Download SDMO R 340 U Specifications
Transcript
User and maintenance manual for generating sets R340U 33504081101NE_0_1 CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. If this product contains a gasoline engine WARNING The engine from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm The state of California requires the above two warnings. 1. Preface ............................................................................................................................................................................................ 3 1.1. General recommendations ................................................................................................................................................. 3 1.2. Pictograms and their meanings .......................................................................................................................................... 4 1.3. Instructions and safety regulations ..................................................................................................................................... 8 1.3.1 General advice ................................................................................................................................................................... 8 1.3.2 Risks related to exhaust gases and fuels ........................................................................................................................... 9 1.3.3 Risks related to toxic products ......................................................................................................................................... 10 1.3.4 Risk of fire, burns and explosion ...................................................................................................................................... 10 1.3.5 Risks related to electrical networks .................................................................................................................................. 11 1.3.6 Dangers presented by electric currents (first aid) ............................................................................................................. 11 1.3.7 Risks related to moving the set ........................................................................................................................................ 11 1.4. Identifying sets ................................................................................................................................................................. 12 2. General description ........................................................................................................................................................................ 14 2.1. Description ....................................................................................................................................................................... 14 2.2. Technical specifications ................................................................................................................................................... 17 2.3. Fuel and consumables ..................................................................................................................................................... 19 2.3.1 Specifications ................................................................................................................................................................... 19 2.3.1.1. Oil grades ............................................................................................................................................................ 19 2.3.1.2. Specifications of coolants .................................................................................................................................... 20 3. Installation...................................................................................................................................................................................... 21 3.1. Unloading ......................................................................................................................................................................... 21 3.1.1 Safety during unloading ................................................................................................................................................... 21 3.1.2 Instructions for unloading ................................................................................................................................................. 21 3.1.2.1. Slings .................................................................................................................................................................. 21 3.1.2.2. Fork lift truck ........................................................................................................................................................ 22 3.2. Fluid retention................................................................................................................................................................... 22 3.3. Choice of location ............................................................................................................................................................. 24 3.4. Electricity .......................................................................................................................................................................... 25 3.5. Special arrangements ...................................................................................................................................................... 26 4. Trailer............................................................................................................................................................................................. 27 4.1. Trailer linkage ................................................................................................................................................................... 27 4.2. Check before towing ......................................................................................................................................................... 27 4.3. Operation ......................................................................................................................................................................... 28 4.4. Unhitching the trailer ........................................................................................................................................................ 28 4.5. Implementation for installation .......................................................................................................................................... 29 4.6. Break transmission adjustment ........................................................................................................................................ 29 4.7. Faults and repairs............................................................................................................................................................. 31 4.8. Electrical connection diagram........................................................................................................................................... 32 4.9. Complete wheels technical information ............................................................................................................................ 32 5. Preparation before operating the set ............................................................................................................................................. 33 5.1. Installation checks ............................................................................................................................................................ 33 5.2. Checks after starting the generating set ........................................................................................................................... 33 6. Using the generator set.................................................................................................................................................................. 33 6.1. Pre-Start Inspection.......................................................................................................................................................... 33 6.2. Generator set with TELYS control panel .......................................................................................................................... 35 6.2.1 Control panel presentation ............................................................................................................................................... 35 6.2.1.1. View of the front panel......................................................................................................................................... 35 6.2.1.2. Description of the screen..................................................................................................................................... 37 6.2.1.3. Description of the pictograms in zone 1 .............................................................................................................. 38 6.2.1.4. Description of the pictograms in zone 2 .............................................................................................................. 39 6.2.1.5. Description of the pictograms in zone 3 .............................................................................................................. 40 6.2.1.6. Display of messages in zone 4 ............................................................................................................................ 43 6.2.2 Starting ............................................................................................................................................................................. 47 6.2.3 Switching off ..................................................................................................................................................................... 48 6.2.4 Alarms and faults ............................................................................................................................................................. 48 6.2.4.1. Viewing alarms and faults ................................................................................................................................... 48 6.2.4.2. Activation of an alarm or fault .............................................................................................................................. 49 6.2.4.3. Activation of an alarm and a fault ........................................................................................................................ 50 6.2.4.4. Engine fault codes display................................................................................................................................... 51 6.2.4.5. Horn reset ........................................................................................................................................................... 52 1/285 6.3. Generator set with KERYS control panel .......................................................................................................................... 53 6.3.1 Presentation of the KERYS............................................................................................................................................... 53 6.3.1.1. Operating conditions ............................................................................................................................................ 53 6.3.1.2. Conformity to legal and regulatory requirements ................................................................................................. 54 6.3.2 Description of the KERYS ................................................................................................................................................. 55 6.3.2.1. Identification of the hardware components .......................................................................................................... 55 6.3.2.2. Identification of the software components ............................................................................................................ 58 6.3.3 Description of the Man Machine Interface (IHM / MMI) ..................................................................................................... 59 6.3.3.1. The Man Machine Interface ................................................................................................................................. 59 6.3.3.2. Navigation in the screens ..................................................................................................................................... 62 6.3.4 Configurations................................................................................................................................................................... 67 6.3.4.1. Operating principle ............................................................................................................................................... 67 6.3.4.2. Legends ............................................................................................................................................................... 68 6.3.4.3. Configuration in solo generating set..................................................................................................................... 68 6.3.4.4. Power plant configuration (Several generating sets in parallel) ........................................................................... 71 6.3.5 Connections of the generating sets .................................................................................................................................. 78 6.3.5.1. Recommendations before the connections .......................................................................................................... 78 6.3.5.2. Connections according to the configurations ....................................................................................................... 78 6.3.5.3. Earthing system (Standard only) .......................................................................................................................... 79 6.3.5.4. Facility power outlet ............................................................................................................................................. 83 6.3.5.5. Connecting cable between the generating sets (power plant) ............................................................................. 84 6.3.5.6. Power................................................................................................................................................................... 85 6.3.5.7. Client terminal block............................................................................................................................................. 85 6.3.6 Operation and setting menus ............................................................................................................................................ 86 6.3.6.1. Layout of the menus ............................................................................................................................................ 86 6.3.6.2. Setting of regional parameters ............................................................................................................................. 87 6.3.6.3. Information on the KERYS ................................................................................................................................... 89 6.3.6.4. Operating menus ................................................................................................................................................. 91 6.3.7 Rental configurations ........................................................................................................................................................ 93 6.3.7.1. Choice of application configuration ...................................................................................................................... 93 6.3.8 Use ................................................................................................................................................................................. 102 6.3.8.1. Choice of priority generating set in power plant (if equipped) ............................................................................ 102 6.3.8.2. Starting, tests and stop ...................................................................................................................................... 108 6.3.8.3. Rental options .................................................................................................................................................... 115 7. Maintenance schedule.................................................................................................................................................................. 117 7.1. Reminder of use.............................................................................................................................................................. 117 7.2. Engine ............................................................................................................................................................................. 117 7.3. Alternator ........................................................................................................................................................................ 118 8. Battery .......................................................................................................................................................................................... 119 8.1. Storage and transport ..................................................................................................................................................... 119 8.2. Battery setting into service .............................................................................................................................................. 120 8.3. Check .............................................................................................................................................................................. 120 8.4. Load preconization .......................................................................................................................................................... 121 8.5. Faults and remedies ....................................................................................................................................................... 122 9. Appendix ...................................................................................................................................................................................... 123 9.1. Appendix A – Engine user and maintenance manual ..................................................................................................... 123 9.2. Appendix B - Alternator user and maintenance manual .................................................................................................. 209 9.3. Appendix C - Common spare parts ................................................................................................................................. 269 9.4. Appendix D - List of John Deere - Volvo and Perkins fault codes ................................................................................... 271 2/285 1. Preface 1.1. General recommendations Thank you for choosing an electrical generating set from our company. This manual has been designed to help you operate and maintain your electrical generating set correctly. The information contained in this manual is taken from technical data available at the time of print. In line with our policy of continually improving the quality of our products, this information may be amended without warning. Read the safety instructions attentively in order to prevent any accidents, faults or damage. These instructions must always be followed. You are likely to encounter several warning symbols in this manual. This symbol indicates an immediate danger to human health and life in case of exposure. Failure to follow the corresponding advice entails serious consequences for human health and life in case of exposure. Danger This symbol draws attention to the potential risks to human health and life in case of exposure. Failure to follow the corresponding advice entails serious consequences for human health and life in case of exposure. Warning This symbol indicates a dangerous situation if the warning is not heeded. Failure to follow the corresponding advice risks resulting in minor injury of personnel or damage to any other object in case of exposure. Important In order to obtain optimum efficiency and the longest possible life for the electrical generating sets, maintenance operations must be carried out according to the periods indicated in the attached preventative maintenance tables. If the electrical generating set is used under dusty or unfavourable conditions, some of these periods will be shorter. Ensure that all repairs and adjustments are carried out by personnel who have received appropriate training. Dealers have this qualification, and can answer all of your questions. They can also supply you with spare parts and other services. The left and right sides can be seen from the back of the electrical generating set (the radiator is at the front). Our electrical generating sets have been designed so that damaged or worn parts can be replaced by new or reconditioned parts thereby reducing the out of action period to a minimum. For any replacement of parts, contact your nearest dealer for our company who will have the necessary equipment and can offer properly trained and informed staff to carry out maintenance, parts replacement and even total reconditioning of generating sets. Contact your local dealer for the available repair manuals and to make the necessary arrangements for training personnel in implementation and maintenance. Important Some user and maintenance manuals for the engines fitted to generating sets cover control units and include the start-up and shutdown procedures for the engines. As the generating sets are fitted with control units that are specific to the generating sets, only the information that appears in the documentation for the generating sets' control units should be taken into consideration. In addition, according to the manufacturing criteria of the generating sets, some engines may be fitted with specific electrical wiring different to that described in the engine documentation. 3/285 1.2. Pictograms and their meanings Safety notices are clearly mounted on the equipment to draw the operator's or maintenance technician's attention to the potential dangers and explain the action to be taken in the interest of safety. These notices are reproduced in this publication for ease of identification by the operator. Replace any notice that is missing or illegible. Caution: danger Publications delivered with the generating set must be referred to Caution: risk of explosion Caution: risk of electric shock Protective clothing must be worn Naked flames unprotected prohibited. No smoking Caution: materials toxic Eyes and ears must be protected Entry prohibited to nonauthorised persons Caution: pressurised fluids Periodic maintenance must be carried out Jet washing prohibited Caution: high temperature, risk of burns Battery level must be checked Earth Caution: rotating or moving parts (risk of getting caught in the machinery) Lifting point must be used Caution: product Fork pockets for lifting Retention high tank and lights corrosive level Important: refer to the documentation accompanying the generating set. Important: emission of toxic exhaust gases. Do not use in a confined or badly ventilated area. Figure 1.1 : Pictograms and their meanings 4/285 WARNING: DANGER This symbol warns of a safety hazard. The presence of this symbol indicates a risk of injury. Observe the safety instructions and precautions for use. Important: Carefully read the instructions supplied with the generating set before using or servicing the equipment. WARNING: DANGER Risk of electrocution Do not touch the cables or connections when the generating set is in operation. Switch off the generating set for maintenance operations. DANGER Use diesel fuel only. The fuel is highly flammable, handle with care. Do not smoke near the generating set or expose it to a naked flame or sparks. Shut down the generating set engine before filling the fuel tank. Fill with fuel outside. To prevent fire risks, clean the generating set regularly. Wipe away any dirt and traces of grease or fuel. WARNING: DANGER The exhaust gases from the engine are toxic and can affect health or even cause death. Use the generating set outdoors only, in well ventilated areas, or fit an exhaust extension to discharge the exhaust gases outside. Figure 1.2 : Pictograms and their meanings 5/285 WARNING: DANGER Hot coolant can cause serious burns. Switch off the engine. Do not remove the filler cap until it is completely cold. Do not open the radiator when it is hot. DANGER Rotating parts can cause serious injury. Do not operate the generating set with the doors open. Do not remove the enclosures. Shut down the generating set before any maintenance or servicing operation. DANGER Avoid any contact with the exhaust pipes, turbochargers and silencers. Keep flammable materials away from hot parts. Wait for the machine to cool down completely before touching it. WARNING: DANGER The gas from the battery electrolyte is explosive. Keep the batteries away from any flames. The battery electrolyte (sulphuric acid) is toxic. Risk of poisoning. Figure 1.2 (continued) : Pictograms and their meanings 6/285 WARNING: DANGER A poor earth connection can lead to serious injuries or death. Always connect the earth terminal of the generating set to an external earth terminal. WARNING Voltage selector This function should be used by qualified persons only. WARNING Adjust the output voltage correctly before connecting a load. WARNING The voltage selector must not be used when the generating set is operating. Figure 1.2 (continued) : Pictograms and their meanings 7/285 1.3. Instructions and safety regulations THESE SAFETY GUIDELINES ARE IMPORTANT If you do not understand or have any questions about any point in this manual, contact your dealer who will explain it to you or give you a demonstration. A list of risks and precautionary measures to take follows. You should also refer to any local and national regulations that apply in accordance with your own jurisdiction. KEEP THIS MANUAL This manual contains important instructions which must be followed when installing or carrying out maintenance on a generating set or batteries. 1.3.1 General advice Use The operating and safety instructions must be made known to operating personnel. They will be regularly updated. Read and understand the manuals provided with the generating set, pump unit or lighting column properly. The manufacturer's instructions must remain at the disposal of technicians, if possible in situ. The facility must be operated under the direct or indirect supervision of a person appointed by the operator, who is familiar with the operation of the facility, and the dangers and drawbacks of the products used or stored in the facility. Do not wear loose clothing, or get close to machines in operation. Note that the fans are not clearly visible when the engine is running. Warn personnel present to keep their distance during operation. Do not run the generating set, pump unit or lighting column without refitting the protective covers and closing all the access doors. Never let a child touch the generating set, pump unit or lighting column, even when shut down. Avoid operating the generating set, pump unit or lighting tower in the presence of animals (disturbance, scares, etc.). Engage the parking brake when the generating set or lighting tower on its trailer is installed on the operating site. When chocking the trailer on a slope; ensure that there is nobody in the path of the trailer. Never start the engine without an air filter or exhaust. Engine with turbocharger: never start the engine without fitting the air filter. The compressor wheel rotating inside the turbocharger may cause serious bodily injury. Foreign objects in the inlet pipe may cause mechanical damage. Engine with air preheating (starting components): never use a starting spray or any other similar starter assistance product. Upon contact with the starting component, an explosion may occur in the inlet tube, causing bodily injury. Do not touch the lighting column lights when they are switched on. Maintenance Follow the maintenance table and its instructions. Always use tools in good condition which are suited to the work to be done. Ensure you have understood the instructions before beginning any operation. Goggles should be worn when carrying out maintenance operations and watches, bracelets etc. should be removed. Fit only original parts. Disconnect the battery and the pneumatic starter (if fitted) before undertaking any repairs, to prevent the engine from starting accidentally. Fit a panel over the controls to prevent any attempt to start. Only use the correct crankshaft turning techniques for turning the crankshaft manually. Do not try to turn the crankshaft by pulling it or levering the fan. This method may cause serious bodily or material damage, or damage the vanes of the fan, reducing the service life of the fan. Clean off any trace of oil, fuel or coolant using a clean cloth. Do not use a soapy solution containing either chlorine or ammonia, as these two chemicals prevent bubble formation. Never use petrol or other inflammable substances to clean the parts. Use only approved cleaning solvents. Do not use a high pressure cleaner for cleaning the engine and equipment. The radiator, hoses, electrical components, etc. may be damaged. Avoid accidental contact with parts at high temperatures (exhaust manifold, exhaust). Before any maintenance operation on a lighting column light, cut the electrical power supply and wait for the bulbs to cool down. Consumables Observe regulations in force concerning use of fuel before using your generating set, pump unit or lighting tower. Under no circumstances use seawater or any other corrosive or electrolytic product in the cooling circuit. 8/285 Environment The operator must take the necessary measures to comply with the aesthetics of the site of use. The whole site must be maintained in a good state of cleanliness. The premises must be kept clean, and be regularly cleaned so as to avoid accumulation of dangerous materials or pollutants and dust, which could ignite or cause an explosion. The cleaning equipment must be suited to the risks posed by the products and dust. The presence of dangerous or combustible materials inside premises housing combustion devices shall be limited to the operating requirements. Facilities must be operated under the constant supervision of a qualified person, who must regularly check that the safety devices are operating correctly and ensure that the combustion devices have the correct fuel supply. Apart from the combustion devices, it is prohibited to use fire in any form. This restriction must be clearly displayed. Spreading of waste water, sludge and waste is prohibited. The fuels to be used must correspond to those featured in the declaration file and the specifications recommended by the combustion device manufacturer. The fuel is considered to remain in the same physical state as when it is introduced into the combustion chamber. Burning of waste in the open air is prohibited. Always protect your hands when checking for leaks. Pressurised liquids may penetrate body tissue and cause serious damage. Risk of blood contamination. Drain and dispose of engine oil in a specially provided container (fuel distributors can collect your used oil). Except by special agreement, once closed, the gas supply main unit must only be re-opened by the gas distributor. However, the user may access it under certain conditions. Check these for each site. 1.3.2 Risks related to exhaust gases and fuels Danger The carbon monoxide present in exhaust gases may cause death if the concentration levels in the air breathed are too high. Always use generating sets, pump units or lighting towers in a well-ventilated place where gases cannot accumulate. In case of indoor use: Be sure to evacuate exhaust gases outdoors. Provide appropriate ventilation so that personnel present are not affected. Observe the local regulations in force for generating sets, pump units or lighting towers, as well as local regulations for use of fuel (petrol, diesel fuel and gas) before using your generating set, pump unit or lighting tower. Fuel filling should be carried out when the engine is off (except for generating sets with an automatic filling system). Engine exhaust gases are toxic: do not run the generating set, pump unit or lighting column in unventilated premises. If installed in a ventilated room, additional requirements for fire and explosion protection must be observed. A leaking burnt gas exhaust may increase the sound level of the generating set, pump unit or lighting column. To check on its efficiency, regularly examine the burnt gas exhaust. Pipes must be replaced as soon as their condition demands it. 9/285 1.3.3 Risks related to toxic products Warning Glycol is a toxic product and dangerous if absorbed. The corrosion inhibitor contains alkali. Avoid all contact with the skin and eyes. Read the Do not swallow it. instructions on the packaging. This substance should not come into contact with the eyes. In the event of contact with the eyes, rinse immediately with plenty of water for at least 15 minutes. Avoid prolonged or repeated contact with the skin. In the event of contact with the skin, wash thoroughly with water and soap. CONSULT A DOCTOR IMMEDIATELY. KEEP THE PRODUCT OUT OF THE REACH OF CHILDREN. The anti-rust product is toxic and dangerous if absorbed. Avoid all contact with the skin and eyes. Read the instructions on the packaging. Caution: fuels and oils are dangerous to inhale. Ensure proper ventilation, and use a protective mask. Never expose the equipment to liquid splashes or rainfall, and do not place it on wet ground. The battery electrolyte is harmful to skin and especially eyes. If splashes get into eyes, rinse immediately with running water and/or a 10% diluted boric acid solution. Wear protective eyewear and strong base resistant gloves for handling the electrolyte. 1.3.4 Risk of fire, burns and explosion The engine should not be operated in environments containing explosive products. As not all of the electrical and mechanical components are shielded, there is a risk of sparks forming. Danger Make sure not to create sparks or flames, and not to smoke near the batteries, as the electrolyte gases are highly flammable (especially if the battery is charging). Their acid also poses a risk to the skin, and in particular to the eyes. Never cover the generating set, pump unit or lighting tower with any material during operation or just after shutdown (wait for the engine to cool). Do not touch hot parts such as the exhaust pipe, or put combustible materials on it. Keep all flammable or explosive materials (e.g. petrol, oil, cloth, etc.) out of the way when the set is running. Proper ventilation is required for your generating set, pump unit or lighting column to work properly. Without this ventilation, the engine would very quickly rise to an excessively high temperature, causing accidents or damage to the equipment and to surrounding property. Do not remove the radiator cap if the engine is hot and the coolant is pressurised, due to risks of burns. Depressurise the air, oil and cooling circuits before removing or disconnecting all the fittings, pipes or connected components. Watch out for the possible presence of pressure when disconnecting a device from a pressurised system. Do not try to find pressure leaks by hand. Oil at high pressure can cause bodily damage. Some preservative oils are flammable. Also, some are dangerous to inhale. Ensure proper ventilation. Use a protective mask. Hot oil causes burns. Avoid contact with hot oil. Check that the system is no longer pressurised before carrying out any procedures. Never start or run the engine with the oil filler cap off (oil may splash out). Never coat the generating set, pump unit or lighting column with a thin layer of oil to protect it from rust. Never top up the oil or coolant if the generating set, pump unit or lighting column is running, or if the engine is hot. A generating set can only operate when stationary, and cannot be installed on a vehicle or other mobile equipment, without a prior study taking into account the various specific features of using the generating set. 10/285 1.3.5 Risks related to electrical networks The electrical equipment supplied with the generating set complies with standard NF C15.100 (France), or with the standards of the countries in question. The earth connection must be installed in accordance with the standards in force in each country in question, and with the neutral system sold. Read the manufacturer's identification plate carefully. The values for voltage, power, current and frequency are shown. Check that these values match the supply use. Never accidentally touch stripped cables or loose connections. Never handle a generating set with wet hands or feet. Maintain electrical wires and connections in good condition. Using equipment in poor condition can lead to electrocution and damage to equipment. Always disconnect the power to the equipment or facility (generating set voltage, battery voltage and network voltage) before any operation. The electrical connections must be made in accordance with current standards and regulations in the country of use. Do not use faulty, poorly insulated or provisionally connected wires. Never reverse the positive and negative terminals on batteries when connecting them. This could cause severe damage to the electrical equipment. Follow the wiring diagram supplied by the manufacturer. The generating set should not be connected to any other power sources, such as the mains supply network. In specific cases where there is to be a connection to existing electrical networks, this must only be installed by a qualified electrician, who should take the operating differences of the equipment into account, according to whether the mains supply network or generating set is being used. Protection against electric shocks is ensured by an assembly of specific equipment. If this needs to be replaced, it should be by components with identical nominal values and specifications. If the protective plates (blanking covers) need to be removed to route cables, the protector (blanking cover) must be refitted when the operations are finished. Due to high mechanical stresses, use only strong flexible wiring with rubber sheathing, compliant with IEC 245-4, or equivalent wiring. 1.3.6 Dangers presented by electric currents (first aid) First aid In the event of an electric shock, shut off the power immediately and activate the emergency stop on the generating set or lighting column. If the voltage has not yet been cut off, move the victim out of contact with the live conductor as quickly as possible. Avoid direct contact both with the live conductor and the victim's body. Use a dry plank of wood, dry clothes or other non-conductive materials to move the victim away. The live wire may be cut with an axe. Take great care to avoid the electric arc that will be generated by this. Begin emergency procedures Resuscitation If breathing has stopped, begin artificial respiration at once in the same place the accident took place unless the victim or operator's life could be endangered by this. In the event of cardiac arrest, carry out cardiac massage. 1.3.7 Risks related to moving the set To unload the generating sets, pump units or lighting columns from their transport support brackets under optimum safety and efficiency conditions, you must ensure that the following points are observed: The lifting machinery or equipment is suited to the work required, in good condition and with sufficient lifting capacity. The slings are positioned in the rings provided for this operation, the forklift arms are resting fully underneath all of the base frame cross-beams, or the lifting bars are inserted in the apertures provided for this purpose in the base to lift the entire generating set (according to models). For completely safe working conditions and to prevent damage to the components fitted on the upper edge of the set, pump unit or lighting column, the generating set, pump unit or lighting column must be lifted up with an adjustable boom. All the chains and cables must be parallel with each other, and as perpendicular as possible with the upper edge of the generating set, pump unit or lighting column. If other equipment fitted on the generating set, pump unit or lighting column alters its centre of gravity, special lifting devices may be necessary to maintain correct balance and completely safe working conditions. The ground must be able to withstand the load of the generating set, pump unit or lighting column and its lifting machinery without stress (otherwise, put down beams of sufficient strength in a stable configuration). Position the generating set, pump unit or lighting column as close as possible to its place of use or transport, in a clear space with free access. Never perform work on a generating set, pump unit or lighting tower just hanging from a lifting device. 11/285 1.4. Identifying sets Generating sets and their components are identified by means of identification plates. The precise rules for identifying each major component (engine, alternator etc.) are set out in each manufacturer's documents contained in this manual. Examples of identification plates Generating set Engines Figure 1.2 : Examples of identification plates 12/285 Alternator Cabinet Figure 1.3 : Examples of identification plates 13/285 2. General description 2.1. Description Overview 1 2 3 4 5 6 1 2 3 Control unit External emergency stop Expansion bottle 4 5 6 Protective grilles Chassis Circuit breakers Figure 2.1 : General description of the generating set 14/285 7 8 7 Battery charge alternator 8 Starter batteries Figure 2.1 (continued): General description of the generating set 9 11 13 10 12 9 10 11 Coolant filter Filling with fuel Oil filters 12 13 14 External fuel supply combined tap (optional) Circuit breaker Interchangeable fuel pre-filters Figure 2.1 (continued) : General description of the generating set 15/285 14 Sockets ( voltage 208/120V ) 16/285 2.2. Technical specifications RENTAL POWER / R340U Range / Generating set type Weights and Dimensions Dimensions with standard tank Dimensions l x w x h: 4475 mm x 1410 mm x 2690 mm Weight: 3830 kg dry weight 4300 kg in operating configuration Hood: M228C Noise level: 80 dB à 1 m (0.70) 70 dB à 7 m (0.70) Dimensions with high autonomy tank Dimensions l x w x h: 4527 mm x 1410 mm x 2780 mm Weight: 4520 kg dry weight 5888 kg in operating configuration Hood: M228C-DW Noise level: 80 dB à 1 m (0.70) 70 dB à 7 m (0.70) Output Voltage Hz Phase Load factor 480/277 V 380/220 V 220/127 V 208/120 V 60 60 60 60 3 3 3 3 0.8 0.8 0.8 0.8 Max current (A) Emergency 453 573 989 1046 Emergency power 1 kW / kVA 301.6 / 377 301.6 / 377 301.6 / 377 301.6 / 377 Prime power 2 kW / kVA 274.2 / 342.7 274.2 / 342.7 274.2 / 342.7 274.2 / 342.7 (1) ESP: Stand-by output available for emergency use under variable charge up to 200hrs per year as per lSO 8528-1, no overload available under these service conditions. (2) PRP: Main output available continuously under variable load for an unlimited time period per year as per ISO 8528-1, an overload of 10% one hour every 12 hours is available, as per ISO3046-1. Engine data Manufacturer / model Type Cylinder configuration Cubic capacity Rotation speed Max emergency/prime power at nominal speed Adjustment type VOLVO TAD941GE Turbo 6L 9.36 L 1800 Rpm 344 / 313 kW Electrical Fuel consumption 110 % (emergency power) 100 % main power 75 % main power 50 % main power 79.2 L/h 70.8 L/h 52.8 L/h 37.0 L/h 17/285 Fuel Fuel type Standard fuel tank High autonomy fuel tank Diesel 470 L 1368 L Lubrication Oil capacity with filter Min. Oil pressure Nominal oil pressure Oil consumption (100 % load) Oil sump capacity Type of lubricant 35 L 0.7 bar 6 bar 0,06 L/h 28 L Genlub Cooling Engine capacity with radiator Max coolant temperature Fan power Ventilator air flow Refrigerant type Thermostat 41 L 103 °C 17.8 kW 7.2 m3/s Gencool 82-92°C Alternator data ● Compliant with NEMA MG21 standards, UTE NF C51.111, VDE 0530, BS 4999, IEC 34.1, CSA Type Number of phases Power factor (cos Phi) Number of poles Excitation type Voltage regulator Short-circuit current Number of bearings Coupling ● The alternator is protected against short circuits ● Vacuum impregnation, epoxy winding, IP23 protection rating LEROY SOMER LSA462VL12 3 0.8 4 AREP R450 3 IN 1 Direct Control unit(s) TELYS Standard specifications: Voltmeter, Ammeter, Frequency meter Alarms and faults: Oil pressure, Water temperature, Start failure, Overspeed, Alternator min/max, Battery voltage min/max, Emergency stop Engine parameters: Timer, Oil pressure, Water temperature, Fuel level, Engine speed, Battery voltage KERYS Coupling: pre-programmed coupling mode selector. Electrical measurements: Voltmeter, Ammeter, Frequency meter Alarms and faults: Oil pressure, Water temperature, Start failure, Overspeed, Alternator min/max, Battery voltage min/max, Emergency stop Engine parameters: Timer, Oil pressure, Water temperature, Fuel level, Engine speed, Battery voltage Additional specifications :Coupling Website, Troubleshooting, Assistance and maintenance, plotting and logging, load impact, 8 configurations available, Compliance with international standards… 18/285 2.3. Fuel and consumables All specifications (product features) are given in the motor and alternator maintenance manuals attached to this manual. In addition, we recommend the consumables to be used in the "specifications" section. 2.3.1 Specifications 2.3.1.1. Oil grades Engine Oil Make Type John Deere All MITSUBISHI Volvo All All Make John Deere GenPARTS GenPARTS GenPARTS Type John Deere PLUS-50 GENLUB TDX 15W40 GENLUB TDX 15W40 GENLUB TDX 15W40 GENLUB TDX 15W-40 Top-of-the-range lubricant recommended for diesel engines: for generating sets used under severe conditions. USES: Particularly suited to more modern engines with or without turbochargers, intercoolers, or sophisticated injection systems (e.g. HEUI, injector-pumps). All types of use: can cope with the most demanding applications. Depolluted engines: complies with EURO 2 and EURO 3 technology and can be used with all types of diesel fuel, especially ecological diesel with low sulphur content. PERFORMANCE: ACEA E3 API CH-4 Meets level E3 of the specifications defined by European manufacturers in the ACEA standards 98 edition. ADVANTAGES: Less frequent oil services: this product has been put to the test during thousands of hours of use on worksites under varying conditions, demonstrating its high quality. Conformity with new environmental legislation: adherence to new anti-pollution standards required for new EURO 2 and EURO 3 engines. SPECIFICATIONS: SAE Grade 15W-40 Density at 15°C Cinematic viscosity at 40 °C Cinematic viscosity at 100 °C Viscosity index Dynamic viscosity at -15 °C Pour point Flash point Sulphated ash content (Values given as examples only) 0.883 105 14.1 mm2/s (cSt) mm2/s (cSt) 140 3000 - 30 220 1.4 mPa.s(cP) °C °C % weight 19/285 2.3.1.2. Specifications of coolants Engine Coolants Make John Deere Type All MITSUBISHI All Volvo All Make GenPARTS Mitsubishi GenPARTS GenPARTS Type GENCOOL PC -26°C LLC GENCOOL PC -26°C GENCOOL PC -26°C GenCOOL PC -26 High-protection coolant, approved by manufacturers. GenCOOL PC -26 is a ready-to-use, highly protective coolant which is produced from an antifreeze recommended by the majority of European manufacturers. It is made from antifreeze and G 48 inhibitors. It protects up to -26°C. It is free from nitrates, amines and phosphates. It is a clear, fluorescent orange liquid. REFERENCES/APPROVALS (for the antifreeze): HEAVY GOODS VEHICLE LIGHTER VEHICLES Approved by MTU, MERCEDES BENZ, MAN, KHD, GENERAL Approved by BMW, VOLKSWAGEN, MERCEDES, PORSCHE MOTORS Conforms with VOLVO, OPEL, SEAT and SKODA specifications Conforms with VOLVO, IVECO, VAN HOOL and STAYR TRUCK specifications Conforms with the NF R 15.601 standard REINFORCED ANTI-CORROSION FEATURES: Protects against high-temperature corrosion by oxidisation of ethylene (cylinder head protection). Protects against high-temperature cavitation (top of cylinder and coolant pump protection). Non-corrosive for seals and hoses. Improves the efficiency and longevity of the cooling system. GenCOOL PC -26 is especially recommended for engines fitted with aluminium or light alloy radiators. HIGH TEMPERATURE SUITABILITY: Provides good conditions for thermal exchange. Perfect stability at high temperatures. GenCOOL PC -26 is specially adapted for engines with high power densities. LONG LASTING PROTECTION: High alkaline reserve/stability and longevity of corrosion inhibitors. Maintains its technical properties during prolonged use at high temperatures (neutralisation of acids). Ensures maximum heat transfer without the build up of deposits in the cooling system. GenCOOL PC -26 ensures optimum protection against overheating and corrosion in extreme conditions of vehicle use. PACKAGING/STORAGE: GenCOOL PC -26 is supplied in 210 l metallic barrels with smooth interior linings. It can be stored for 2 years in its original container and packaging. Avoid zinc coated containers. 20/285 RECOMMENDATIONS FOR USE: Compatible with the original fluid. It is recommended that the cooling system is completely drained when replacing the fluid. UNITS SPECIFIED VALUES TRIAL METHODS kg/m3 1,059 +/- 3 R 15-602-1 pH pH 7.5 to 8.5 NF T 78-103 Alkalinity reserve ml >=10 NF T 78-101 Boiling point °C 105 +/- 2 R 15-602-4 Freezing point: Glassware corrosion : (test with antifreeze) °C -26 +/- 2 NF T 78-102 SPECIFICATIONS Density at 20°C mg/test piece R 15-602-7 - Copper +/- 2.6 - Weld +/- 0.5 - Brass +/- 2.3 - Steel +/- 1.6 - Cast iron +/- 0.8 - Cast aluminium Corrosion on warm plate (test with antifreeze) +/- 1.0 mg/(cm²week) +/- 0.17 R 15-602-8 3. Installation 3.1. Unloading 3.1.1 Safety during unloading To unload electrical generating sets from their transport supports under optimum safety and efficiency conditions, you need to ensure that the following points are observed: - Lifting machinery or equipment appropriate to the work required. - Slings positioned in the eyes provided for this operation or lifting arms resting fully underneath the chassis cross members. - Ground able to take the load of the set and the lifting machinery without stress (otherwise lay down beams of sufficient strength and stability). - Set put down as close as possible to its point of use or transportation, in a clear area with free access. Example of equipment to be used: crane, slings, cross bar, safety catch, shackles. Fork lift truck. 3.1.2 Instructions for unloading 3.1.2.1. Slings Attach the lifting vehicle slings to the rings on the generating set designed for this procedure. Hang the slings carefully. Check that the slings are correctly attached and the equipment is solid. Lift the generating set carefully. Direct and stabilise the set towards the chosen position. Carefully set down the equipment while continuing to position it. Release the slings, then detach and remove the lifting rings. 21/285 3.1.2.2. Fork lift truck Position the forklift arms under the base frame (except with generating sets fitted with "forklift pockets", in which case position the forklift arms in these pockets), making sure that only its cross-members are resting on the arms. Lift the equipment, handling it gently. Set down the generating set in its unloading position. Figure 3.1: Transporting a generating set using a forklift truck 3.2. Fluid retention Any outflow of the fluids contained in the generating sets (fuel, oil and coolant, or rainwater or condensation) will be collected in a retention container if the generating set is fitted with this option. The containers have a capacity which allows 110% of the fluids contained in the generating set fitted with this option to be collected. Three different fittings are available. Figure 3.2: Fluid retention container integrated into the tank chassis. 22/285 Figure 3.3: Offset fluid retention container underneath the generating set chassis. Figure 3.4: Offset fluid retention container integrated into the chassis and tank. Generating sets fitted with the offset tank option (DW) above also have a high level indicator in the retention container. In all cases, the retention containers must be regularly checked to ensure they contain no fluid (fuel, oil and coolant, or rainwater or condensation). If necessary, drain the containers either via the drain port or by using the drain pump (for containers fitted with this pump). Note: Never allow these fluids to drain onto the ground; ensure they are collected in a designated container. 23/285 3.3. Choice of location It should be determined on the basis of use. There are no specific rules governing the choice of location, other than proximity to the electric distribution panel and disturbances caused by the noise. However, fuel supply, burnt gas evacuation, and the direction of these gases and the noises emitted should be taken into account. The choice of its position will be based on carefully considered compromise! Examples of problems that may be encountered: Incorrect exhaust and ventilation Ground too uneven or soft. Set incorrectly positioned Fuel filling impossible Reduced access Opening cover doors impossible Figure 3.5: Examples of problems that may be encountered 24/285 3.4. Electricity a) Connections - general information As with low voltage electrical installations, use and maintenance is governed by standard NFC 15.100 (France) or by the standards in the relevant country, based on international standard IEC 60364-6-61. They must also adhere to the regulations in the NFC 15.401 application guide (France) or to the regulations and standards in the relevant country. b) Power cables These can be unipolar or multipolar according to the power of the generating set. Power cables should preferably be installed in ducts or on a cable tray for this purpose. The cable cross-section and number of cables should be determined according to the cable type and the current standards to be observed in the country of installation. The choice of conductors must comply with international standard IEC 30364-5-52. Three phase - Calculation hypothesis Fitting method = wiring in cable runs or non perforated trays. Permissible voltage drop = 5% Multiconductors or single conductor joined when precision 4X…(1) Cable type PVC 70°C (e.g. H07RNF). Ambient temperature = 30°C. Cable sizes Circuit breaker calibre (A) 10 16 20 25 32 40 50 63 80 100 125 160 250 400 630 (1) (1) (1) (1) (1) 0 - 50m mm²/AWG 1.5 / 14 2.5 / 12 2.5 / 12 4 / 10 6/9 10 / 7 10 / 7 16 / 5 25 / 3 35 / 2 4X(1X50) / 0 4X(1X70) / 2/0 4X(1X95) / 4/0 4X(1X185) / 0400MCM 4X(2X1X150) / 2x 2350MCM 51 - 100m mm²/AWG 2.5 / 12 4 / 10 4 / 10 6/9 6/9 10 / 7 10 / 7 16 / 5 25 / 3 35 / 2 4X(1X50) / 0 4X(1X70) / 2/0 4X(1X150) / 2350MCM 4X(1X185) / 0400MCM 4X(2X1X150) / 2x 2350MCM 101 - 150m mm²/AWG 4 / 10 6/9 6/9 10 / 7 10 / 7 16 / 5 16 / 5 25 / 3 35 / 2 4X(1X50) / 0 4X(1X70) / 2/0 4X(1X95) / 4/0 4X(1X150) / 2350MCM 4X(1X185) / 0400MCM 4X(2X1X150) / 2x 2350MCM Single phase - Calculation hypothesis Fitting method = wiring in cable runs or non perforated trays. Permissible voltage drop = 5% Multiconductors. Cable type PVC 70°C (e.g. H07RNF). Ambient temperature = 30°C. Circuit breaker rating (A) 10 16 20 25 32 40 50 63 80 100 125 Cable sizes 0 - 50m 51 - 100m 101 - 150m mm²/AWG 4 / 10 6/9 10 / 7 10 / 7 10 / 7 16 / 5 16 / 5 25 / 3 35 / 2 35 / 2 50 / 0 mm²/AWG 10 / 7 10 / 7 16 / 5 16 / 5 25 / 3 35 / 2 35 / 2 50 / 0 50 / 0 70 / 2/0 95 / 4/0 mm²/AWG 10 / 7 16 / 5 25 / 3 25 / 3 35 / 2 50 / 0 50 / 0 70 / 2/0 95 / 4/0 95 / 4/0 120 / 2250MCM c) Battery cables Install the battery or batteries in the immediate vicinity of the electric starter motor. The cables will be connected directly from the battery terminals to the starter motor terminals. The primary instruction to follow is to ensure that the polarities between the battery and starter motor match. Never reverse the positive and negative battery terminals when connecting them. This could cause severe damage to the electrical equipment. The minimum cross-section of the cables will be 70 mm2. It varies according to the power of the starter motor but also the distance between the batteries and the set (voltage drops on the line). 25/285 d) Safety guidelines References: NFC 15-100:2002 (France) - IEC: 60364-5-54 In order to protect personnel against electric shocks, this generating set is equipped with a differential residual current protector "factory" set to trigger instantly, with a sensitivity of 30 mA. Important Any modification to this setting could endanger personnel. Any modification would render the user liable, and must only be performed by qualified and authorised personnel. When the generating set is disconnected from a facility after use, the master differential protector must be returned to its "factory" settings, and this must be checked by trained personnel. For effective protection against electric shocks, the generating set needs to be earthed. To do this, use a copper wire, with a minimum cross-section of 25 mm2 for a stripped cable and 16 mm2 for an insulated cable, connected to the generating set earth socket and a galvanised steel earthing rod embedded vertically into the ground. The earthing rod resistance value should comply with the values shown in the table below. Note: use the highest differential setting from the installation as a guideline. The resistance value is calculated in the following way: R = Ul I Δn Maximum resistance value of the earth socket R (Ω) according to the differential unit operational current (operation time should not be longer than 1 second). I Δn differential Earth R (Ω) Ul: 50 V 500 500 167 100 50 17 10 5 ≤ 30 mA 100 mA 300 mA 500 mA 1A 3A 5A 10A Earth R (Ω) Ul: 25 V > 500 250 83 50 25 8 5 2.5 The Ul value: 25 V is required for work site installations, and livestock buildings, etc. For a default voltage of 25 V and a default current of 30 mA, this rod must be of a minimum length of: see table below: Nature of ground Thick arable land, moist compact ballast Lean arable land, Gravel, coarse ballast Bare stony soils, dry sand, impermeable rock Length of rod in metres 1 1 3.6 To obtain an equivalent length, you can use several earthing rods connected in parallel and set apart by at least their length. Example: 4 interconnected 1 metre rods separated by 1 metre. Note: For the United States (National Electrical Code reference NFPA-70). The generating set must be earthed. To do this, use a copper wire with a minimum cross-section of 13.3 mm² (or AWG 6, at most) connected to the generating set earth socket and a galvanised steel earthing rod fully embedded into the ground vertically. This earthing rod embedded fully in the ground must have a minimum length of 2.5 m. 3.5. Special arrangements Generating sets are not fitted with protection against power surges caused by drops in atmospheric pressure or manoeuvring. The company does not accept any responsibility regarding damage caused by these occurrences. However, lightning conductors can be installed, on the understanding that this does not give total protection. 26/285 4. Trailer 4.1. Trailer linkage Before attaching the trailer, check the trailer hook on the tow vehicle; it should fit the trailer ring perfectly. Warning Trying to tow a trailer with a non-matching device (bar, wires, cords, etc.) could lead to serious accidents. Also check: - no incipient fractures or excessive wear on the hitching system. - locking system is operating properly. To hitch the trailer, proceed as follows: Lock the wheels to stop the trailer from moving Lift up the rear trailer supports and lock them Release the parking brake Release the locking levers for the draw bar arms and adjust the ring to the same height as the vehicle hook Hitch the trailer, remove the locks on each side of the wheels then lift up the front wheel fully using its handle Connect the electrical circuit of the trailer to that of the tow vehicle Hook the handbrake safety wire onto the hook on the tow vehicle. CORRECT CORRECT Tow vehicle Tow vehicle Trailer Trailer INCORRECT INCORRECT Tow vehicle Tow vehicle Trailer Trailer Figure 4.1 : Coupling a trailer 4.2. Check before towing Before towing, check the following: Tightness of the generating set enclosure bolts. Wheel tightness. Hitching hook locked. Tyre pressure. Signalling lights working, for "on-road" trailers. Enclosure doors closed. Parking brake released, for "on-road" trailers. Guide wheels (jockey wheels) and stands lifted (if fitted). Towbar arm locking levers tightened and pinned (if fitted with an adjustable towbar). Brake test, for "on-road" trailers. Safety cable fitted, for "on-road" trailers. 27/285 4.3. Operation "On-site" trailer These trailers are not fitted with a main brake, and so cannot be braked in motion; the tyres allow for a maximum speed of 27 km/h. So it is absolutely prohibited to exceed this speed. Nor are these trailers fitted with signalling lights. On-road use is prohibited. "On-road" trailer The driving speed must be suited to the condition of the road and the handling of the trailer. Driving at high speed causes heating of the tyres; so it is important to stop from time to time, and check them. Excessive heating may cause a puncture, and therefore a serious accident. For reversing manoeuvres, remember to lock the inertia brake. Particular attention must be paid to the tightness of the wheels on new vehicles. In the first few miles' driving, heating of the brake hubs and drums will actually reduce the wheel tightness. It is therefore essential to check the tightness every 6 miles (10 kilometres) until no further loosening is noted. Nonetheless the tightness must be checked whenever you are about to tow the trailer. Warning Lights/signalling (only for "on-road" trailers) Warning lights are obligatory for on-road driving. Signalling must comply with regulations in force in the country of use. Front reflective devices (white) Red rear lights + direction indicators + stop lights Rear reflective (red triangle) devices Side reflective devices (orange) Figure 4.2: Example of French signalling 4.4. Unhitching the trailer This operation should be carried out on horizontal, flat, stable ground. Lock the wheels Lower the front wheel Disconnect the road signals wire Refit the hitch using the wheel to release the hook ring from the tow vehicle, Release the tow vehicle Engage the handbrake. 28/285 4.5. Implementation for installation Operations to be carried out: Ensure that the ground is strong enough for the assembly not to sink into it. Unhitch the trailer. Immobilise the trailer by placing chocks under the wheels. Fully engage the parking brake (if fitted). Using the front wheel, position the generating set as close to horizontal as possible. Lower the stands (if fitted), and lock them. 4.6. Break transmission adjustment - The handbrake is used only as a parking brake. - Setting is carried out starting with the brakes moving to the brake control. Important After fitting the wheels on the axle, turn the wheels in the FORWARD direction (on all RA 2 type brakes, check that the adjustment screw 8 reaches the “FORWARD” stop on the brake backing plate). Adjust the brake setting using screw 8, with the cables not connected to the cross bar(s). The shoes should rub the drum slightly. Connect the brake cables to the cross bars(s) and tighten the nuts and lock nuts, leaving the end of the threaded end protruding by around 10 mm (Fig. 4.4). IMPORTANT: Wherever possible, cables must cross over to achieve the highest possible gain curve (Fig. 4.5). Check that the parking lever 1 is in the ‘REST” position and that the compensating spring 4 is completely free on its rod (unscrew the nuts 5 fully). Check that the hook slide 2 is not compressed and the yoke 3 is in the pulled out position. Fit the transmission and adjust the assembly using the tensioner 6 until a gap (J1) of 1 mm max is obtained between the linkage 9 and slide 2. Adjust the compensating spring 4 at one end pressing it against the anchorage plate, and at the other end leaving a 2 mm gap (J2) max between the spring and nuts 5. Tighten all the lock nuts. Checking the setting (trailer on axle stands): Pull the parking lever 2 notches - the wheels cannot turn in a FORWARD direction. The wheels can turn in REVERSE (adjustment screw 8 switches to the REAR position). Pull the parking lever fully. The wheels will not turn either in FORWARD or REVERSE and the cross bar(s) must remain parallel with the axle body. Check the transmission setting after 180 miles (300 km) (running in period) and if necessary adjust the gap (J1) using the tensioner. Parking The lever must be fully pulled up, so that the compensating spring is fully compressed. Every 900 miles (1500 km), check the braking settings and distribution on all the wheels. Important The brake controls are designed to draw trailers behind flexible suspension touring vehicles. If used behind an HGV, be sure to provide the fitted ball joint with a shock absorber to prevent premature wear. During any manoeuvres with the trailer coupled, do not turn more than 90° or force reverse. The specifications of our brake controls are indicated on a manufacturer's plate, and the items on this should be supplied to us when requesting replacement parts, in particular for the shock absorber, of a special type, approved by the Service des Mines to correspond to European standards (it is advisable to have a spare shock absorber to enable instant repairs). 29/285 Figure 4.3: Braking transmission Figure 4.4: Cross bar fitting Figure 4.5: Tandem bearing fitting 30/285 4.7. Faults and repairs Fault observed Erratic braking of trailer Braking too weak Drum temperature abnormally high Jerky braking Origin - Faulty shock absorber - Jaws worn - Jaws not run in - Incorrect linkage setting - Significant friction on the slide - Slide corrosion - Coupling height does not match that of the towing vehicle - Incorrect linkage setting - Incorrect brake setting - High levels of dust in the drums - Jaws, springs, drums damaged - Brake cables or link rod damaged - Incorrect linkage setting - Interfering parts on the slide - Corroded slide - Damage to slide guide rings - Faulty shock absorber - Cross-bar(s) not balanced - Different brake setting on the two sides Trailer tending to swerve upon braking - Cables damaged or incorrectly fitted - Poor load distribution - Damage to slide or to guide rings - Slide corrosion When starting the trailer holds back the towing vehicle - Tie rod damaged - Linkage damaged or incorrectly set Play in the coupling head Parking braking too weak - Brake on - Head worn (see wear indicator) - Ball joint worn - Compensating spring incorrectly set - Braking system incorrectly set - Notched sector damaged - Lever ratchet worn - Cable ruptured 31/285 Solutions Replace the shock absorber Replace the jaws Fault will disappear only after running in Adjust the setting Grease the sliding parts Remove the corrosion and grease Adjust the height so that the two parts are in the same horizontal plane Adjust the settings Adjust the settings Remove the dust Replace the damaged parts Replace the damaged parts Adjust the settings Remove, clean and grease Remove the corrosion and grease Replace the rings (and possibly the slide) and grease Replace the shock absorber Adjust the cross-bar(s) Adjust the brake settings Replace the damaged parts Refit the cables Check the load distribution Replace the faulty parts and grease Remove the corrosion and grease Replace the tie rod and adjust the settings Replace the damaged parts and adjust the settings Loosen the brake Replace the head Replace the ball joint Adjust the setting Adjust the setting Replace the sector and adjust the setting Replace the lever and adjust the setting Replace the cable and adjust the setting 4.8. Electrical connection diagram Figure 4.6 : Electrical connection diagram 4.9. Complete wheels technical information TYRES 550 566 578 534 548 594 622 Cross section (mm) 134 145 150 150 147 185 172 Radius under load (mm) 265 272 277 259 263 285 284 100 N 525 155 244 102 P 650 188 316 106 P 666 98 N 450 (2) Wheel with 5 holes 198 190 32 - Dimensions Indices Diameter (mm) 135 R 13 145 R 13 155 R 13 145/70 R 13 155/70 R 13 185/70 R 13 165 R 14 C 70 T 75 T 79 T 71 T 75 T 86 T 98 N 155/70 R12 185 R 14 C 195 R 14 C 195/50 x 10 (1) Wheel with 4 holes 32/285 COMPLETE WHEELS Pressure Load (bar) (Kg) 335 2.4 387 2.4 437 2.4 345 2.5 387 2.5 530 2.5 650 3.8 (1) 650 6.25 800 (2) (1) 675 4.5 850 (2) 950 4.5 750 6.0 5. Preparation before operating the set The inspections referred to in this section enable the electrical generator set to operate. Specific skills are required to carry out these operations. They must only be entrusted to personnel with the necessary skills. Failure to follow these instructions in any way could result in malfunction or very serious accidents. Danger 5.1. Installation checks Check that the general recommendations given in the installation section (ventilation, exhaust, fluids, etc.) are observed. Carry out the level checks (oil, water, diesel fuel, battery). Check the generating set earth connection is earthed. Check that the electrical connections are in order. 5.2. Checks after starting the generating set Carry out the mechanical checks (oil pressure, water temperature, absence of noise etc.) Carry out the electrical checks (voltage and frequency) Carry out the safety checks (emergency stop, oil pressure, water temperature etc.) 6. Using the generator set 6.1. Pre-Start Inspection • Engine and engine compartment, general check Visually check the engine and engine compartment before starting the engine and after stopping the engine. Check: there are no oil, fuel or coolant leaks, the screws are tightened, the condition of the belts (wear, tension). Fuel, oil and grease deposits on the engine or in the engine compartment are always a fire hazard and must be removed as soon as they are noticed. Warning If there are any oil, fuel or coolant leaks, locate the origin of the fault and repair it immediately before starting the engine. Important Never use a high pressure cleaner for cleaning the engine and equipment. Important • Oil level, check and top up Check the oil level every day before the first start-up. Check that it is between the MAX and MIN marks on the oil dipstick. If necessary, top up the oil through the filler opening, on the left-hand side of the engine. Before checking the level again, wait a few minutes for the oil to drain into the sump. Never fill oil past the maximum level. Only use oil of the recommended grade. Important 33/285 • Coolant level, check Do not open the filler cap when the engine is hot, except in an emergency. Boiling liquid or vapour may be ejected. Warning Important The system must be filled up with liquid which has identical proportions to that already contained in the cooling system. Only open the filler cap (1). The coolant level must be between the MIN and MAX marks. Top up the oil if necessary. • Checking the air filter clogging indicator Special air filters must be used for extremely dusty conditions. Important Replace the filter when the indicator remains in the red zone after the engine has been stopped. Reset the indicator after the filter has been replaced by pressing the button. 34/285 6.2. Generator set with TELYS control panel 6.2.1 Control panel presentation 6.2.1.1. View of the front panel 9 1 13 6 7 9 5 12 2 3 9 8 10 11 4 9 Figure 6.4 : View of the front panel 1 2 3 4 5 6 7 8 9 10 11 12 13 Emergency stop button (AU) for switching off the generating set in the event of a fault which could endanger personnel or damage equipment. Key switch for switching the module on/off. Electronic board protection fuse. Scrolling and selection wheel for scrolling through the menus and screens and selecting items simply by pressing the wheel. STOP button, press to switch off the generating set. START button, press to switch on the generating set. Power ON LEDs and alarm/fault warning LEDs. Location of USB ports. Mounting bolt. LCD for displaying alarms and faults, operating statuses, electrical and mechanical quantities. ESC button: for returning to the previous selection and for default RESET function. MENU button for accessing the menus. Lighting for the emergency stop button. 35/285 1 2 3 Figure 6.5 : Description of the LEDs A lit LED indicates: 1 Alarm activated (flashing yellow). 2 Fault found (flashing red). 3 Module on (green, on continuously). 1 2 3 Figure 6.6: Close-up of USB ports 1 2 3 USB key connection (HOST): file transfer between USB key and TELYS and vice versa. Connection for microcomputer (DEVICE): file transfer between PC and TELYS and vice versa, main module power supply. Protective cover. 36/285 6.2.1.2. Description of the screen The screen is backlit and requires no contrast adjustments. This screen is divided into 4 zones. SERIAL No.: 08030010000 SOFTWARE: 5.3.5 NOMINAL VOLTAGE: 400V FREQUENCY: 50Hz NOMINAL KW: 320kW EARTH SYSTEM: TNS Figure 6.7: Description of the screen (example) Zone 1: in this zone, the status of the generating set is displayed Zone 2: in this zone, pictograms relating to dimensions measured are displayed, as well as Alarm and Fault pictograms Zone 3: in this zone, the measured values corresponding to the measured dimensions are displayed with the corresponding units of measurement Zone 4: in this zone, messages relating to the control of the generating set and the menus are displayed. Note: the information displayed on measurements, alarms and faults as well as messages and menus relating to control of the generating set will depend on the equipment level of each generating set. Certain screens may therefore not be present. 37/285 6.2.1.3. Description of the pictograms in zone 1 Pictograms in zone 1 Pictograms Activation conditions TELYS in manual mode (MANU) Display Fixed "MANU" Mode Flashing For 5 seconds when switching from AUTO mode to MANU mode Fixed TELYS in automatic mode (AUTO) Flashing For 5 seconds when switching from MANU mode to AUTO mode Flashing Generating set in start-up phase Fixed Generating set started Fixed Generating frequency) "AUTO" Mode Flashing (appearance of movement from left to right) Fixed constant set The generating installation stabilised set is The installation is supplied Not used Not used 38/285 (voltage and powering the 6.2.1.4. Description of the pictograms in zone 2 Alarm and fault pictograms in zone 2 All the pictograms in this zone are activated when TELYS is initialised. Data displayed Fuel level indicator Alarm / Fault high fuel level Alarm / Fault low fuel level Alarm Low level fault High level fault alarm Coolant level / temperature indicator Alarm High temperature fault Battery Min battery voltage (flashing) No preheating fault alarm Battery charge indicator (flashing bars) Max battery voltage (flashing) Oil pressure Alarm / Fault Oil pressure / temperature indicator High or low oil level Alarm / Fault Emergency stop High or low oil temperature Alarm / Fault Emergency stop fault Overload or short circuit Tripping of circuit breaker following an overload or short circuit Engine speed Underspeed fault Overspeed fault 39/285 Non-starting fault 6.2.1.5. Description of the pictograms in zone 3 Pictograms in zone 3 All the pictograms in these zones are activated when TELYS is initialised. The pictograms below are given as examples. Generating set stopped Screen no. Pictograms Data displayed Fuel Level Indicator Indication of Temperature of High Temperature coolant (HT) (units according to settings menu) P1 Indication of Battery Voltage Indication of Oil Temperature (units according to settings menu) Generating set start-up or generating set started or generating set switching off in progress Screen no. Pictograms Data displayed Engine Speed Indication Indication of Temperature of High Temperature coolant (units according to settings menu) P2 Indication of Oil Pressure (units according to settings) Indication of Oil Temperature (units according to settings menu) 40/285 Generating set started Screen no. Pictograms Data displayed Fuel Level Indicator P3 Default screen in operation Alternator composite Voltage Indicator Total Active Power Indicator Alternator Frequency Indicator U12 Alternator composite Voltage Indicator U23 Alternator composite Voltage Indicator P4 U31 Alternator composite Voltage Indicator Alternator Frequency Indicator V1 Alternator single Voltage Indicator V2 Alternator single Voltage Indicator P5 V3 Alternator single Voltage Indicator Alternator Frequency Indicator U12 Alternator composite Voltage Indicator V2 Alternator single Voltage Indicator P6 V1 Alternator single Voltage Indicator Alternator Frequency Indicator V1 Alternator single Voltage Indicator P7 Single phase Alternator current indicator Alternator Frequency Indicator 41/285 Screen no. Pictograms Data displayed Single phase Alternator current indicator Two phase Alternator current indicator P8 Three phase Alternator current indicator Neutral Alternator current indicator Total Active Power Indicator Total Reactive Power Indicator P9 Total Effective Power Indicator Total Power Factor Indicator (lagging or leading) Fuel Level Indicator P10 Indication of Battery Voltage Indication of Battery Amps Screen order of appearance according to network type with the generating set on. Type of network Order of appearance 1 2 3 4 5 6 7 3P+N P3 P4 P5 P8 P9 P2 P10 3P P3 P4 P8 P9 P2 P10 Change screens by using the scrolling and selection wheel. When the wheel is rotated clockwise, the screens scroll upwards and vice-versa. The screens scroll in a loop. E.g.: On three-phase + neutral network, then screen 7, then screen 1 and vice-versa. 42/285 2P+N P3 P6 P8 P9 P2 P10 1P+N P3 P7 P9 P2 P10 6.2.1.6. Display of messages in zone 4 The display (zone 4), among other things, displays messages relating to the operation of the generating set. The messages are as follows: Initialisation of TELYS Screen no. Screen Data displayed Initialisation of TELYS when the power is switched on and/or when loading a configuration G1 G2 Generating set serial no. Software version of TELYS Alternator Nominal Voltage Alternator Nominal Frequency Nominal Active Output Neutral Point Bar graph indicating the display delay of the screen SERIAL No.: 08030010000 SOFTWARE: 6.1.0 NOMINAL VOLTAGE: 400V FREQUENCY: 50Hz NOMINAL KW: 320kW EARTH SYSTEM: TNS 43/285 Generating set stopped Screen no. Screen Data displayed OPERATION MANUAL Operating mode - generating set in Manual Mode ready to start Date and time (depending on settings) Press START to start G3 24/08/2005 13:12 OPERATION AUTO WARNING START-UP POSSIBLE IMMEDIATELY G4 24/08/2005 Operating mode - generating set in Auto Mode ready to start Date and time (depending on settings) 13:12 WARNING Operating mode - generating set in Auto Mode with programmed start Countdown to micro disconnection delay or EJP notice delay (for France only) Date and time (depending on settings) AUTOMATIC Start 19 min 30 sec G5 24/08/2005 13:12 Generating set start-up Screen no. G6 Screen Data displayed START-UP IN PROGRESS 24/08/2005 Operating phase - generating set in starting phase Date and time (depending on settings) 13:12 AIR PREHEATING Operating phase - air preheating prior to starting generating set Countdown for air preheating delay Date and time (depending on settings) G7 10 seconds 24/08/2005 13:12 44/285 Generating set started Screen no. Screen Data displayed AVAILABLE POWER G8 Default screen Operating phase – generating set in operation – stable voltage and frequency Available power Date and time (depending on settings) 75% 24/08/2005 13:12 AUTOMATIC STOP IN PROGRESS G9 Operating mode - operation in Auto Mode Opening of power supply device (motorised circuit breaker or source changeover switch controlled by TELYS) Countdown for the mains return delay OR the load test delay Date and time (depending on settings) LOAD SUPPRESSION 1 min 30 sec 24/08/2005 13:12 AUTOMATIC STOP IN PROGRESS G 10 Operating mode - operation in Auto Mode Generation set cooling in progress Countdown for Engine Stop delay (cooling) OR Gradual Stop delay (Coolant temperature) OR Overload Gradual Stop delay OR OFF load test delay Date and time (depending on settings) COOLING DOWN 1 min 30 sec 24/08/2005 13:14 Generating setstop Screen no. G 11 Screen Data displayed OFF IN PROGRESS 24/08/2005 Generating set stop in progress Date and time (depending on settings) 13:16 45/285 Operating mode changeover (switching from Manual Mode to Auto Mode following auto start demand) Screen no. G 12 Screen Data displayed Start Demand AUTO Do you wish to change to Auto Mode? WARNING Immediate start OK Operating mode - operation in Manual Mode AUTOMATIC start demand Esc Generating set stop request due to fault or by pressing STOP in Auto Mode Screen no. Screen Data displayed Manual Mode activated G 13 Do you wish to change to AUTO mode? OK Operating mode - operation in Auto Mode (generating set in operation) Warning message for switching to Manual Mode after the STOP button has been pressed or a fault has appeared Esc 46/285 6.2.2 Starting Check that the generating set circuit breaker has triggered. Danger Connect the generating set battery Turn the key switch to the ON position (without forcing it to the ON position), the ON lamp will light up (if the lamp does not light up, check and replace the fuse if necessary) Test the Alarm and Fault LEDs (menu 15 – TEST LAMPS) 1 ACTIONS 1/5 11 MANUAL <> AUTO 12 CONTROL LOAD 13 TEST GENERATING SET 14 PROGRAMS 15 TEST LAMPS 12 OK Esc Press "Esc" several times to return to the following home menu OPERATION MANUAL Press START to start 24/08/2005 13:12 Check the battery voltage Press START: AVAILABLE POWER AIR PREHEATING START-UP IN PROGRESS 100.0% 10 seconds 13:12 If the engine is equipped with an air preheating system, there is a delay (adjustable) before the engine starts (preheating activation period). If the motor is not fitted with an air preheating system or once the preheating delay has elapsed, the engine starts up (start of a cycle comprising 3 attempts to start up the engine). 24/08/2005 13:12 Warning: the number of successive and automatic starting attempts is limited to 3. 24/08/2005 13:12 The following pictogram is displayed The following pictogram will flash The following information is displayed Speed of rotation Coolant temperature Oil pressure Oil Temperature 47/285 Options 24/08/2005 6.2.3 Switching off Open the circuit breaker manually OR by selecting menu 12 "CONTROL LOAD" The following display will disappear (supply stopped) Press the STOP button The following screen is displayed and the generating set will stop OFF IN PROGRESS 24/08/2005 13:12 Switch TELYS off by turning the key to "OFF" (without forcing it to the "OFF" position). 6.2.4 Alarms and faults 6.2.4.1. Viewing alarms and faults Alarms and faults are displayed as follows: Alarms All alarms will cause: the yellow LED to flash "General alarm". In conjunction with this LED: a flashing pictogram appears on the LCD screen representing the circuit affected by the alarm and the associated indicator, if present (example) message on graphic display (example) FAULT ALARM Low Fuel Level 25/12/05 15:30 OK=HELP Faults All faults will cause: the generating set to stop: immediate or gradual stop (coolant temperature and overload or short circuit) the red LED to flash "General fault". 48/285 In conjunction with this LED: a flashing pictogram appears on the LCD screen representing the circuit affected by the fault and the associated indicator, if present (example) message on graphic display (example) FAULT FAULT Oil Pressure 25/12/05 15:30 OK=HELP Faults have priority over alarms. Faults are displayed in the descending order of their appearance (from the most recent to the oldest). 6.2.4.2. Activation of an alarm or fault The appearance of an alarm or a fault causes the corresponding screen to be displayed (examples below) FAULT FAULT ALARM Low coolant Level 06/10/06 10:30 FAULT Emergency Stop 06/10/06 15:30 Esc=RESET OK=HELP OK=HELP Press OK (on the scrolling and selection wheel) to access the help message if it is available (example below) HELP Check the level fuel Esc=EXIT If the alarm is no longer active, it is reset automatically (cause disappears). Press Esc to reset a fault: reset acknowledged if the cause of the fault has been removed reset not performed if the cause of the fault is still present. 49/285 6.2.4.3. Activation of an alarm and a fault The appearance of an alarm and a fault causes: The yellow and red LEDs to flash the related screen to be displayed (example below) FAULTS 1/2 FAULT Emergency Stop 25/12/05 15:30 Esc=RESET If several faults are present, the number of faults is displayed at the top of the screen. OK=LIST The faults list can be accessed by pressing OK (of the scrolling and selection wheel) (examples below) FAULTS 1/2 FAULT 25/12/05 15:30 Emergency Stop ALARM 25/12/05 15:30 Low Fuel Level 12 OK=HELP Press Esc to return to the previous screen. Press OK to go to the HELP screen (help on the highlighted fault) Use the scrolling and selection wheel to scroll through the list of faults. Esc HELP Check: - Emerg. Stop Pos. - Connector(s) Esc If the alarm is no longer active, it is reset automatically (cause disappears). Press Esc to reset a fault: reset acknowledged if the cause of the fault has been removed reset not performed if the cause of the fault is still present. 50/285 6.2.4.4. Engine fault codes display Certain alarms and engine faults generate specific fault codes. These codes are standardised according to the J1939 and/or J1587 standards, except for MTU engines that have a specific transmission protocol (see appendix, if applicable). Terminology used by the SAE CAN J1939 standard SPN: Suspect Parameter Number This represents the system or component at fault, for example: SPN 100, indicates an oil pressure problem or a problem with the oil pressure sensor. FMI: Failure Mode identifier This represents the type of fault that has occurred. This may be an electrical, mechanical or equipment fault. Terminology used by VOLVO SID: System Identifier This term, used in the J1587 standard, has an equivalent in the J1939 standard (SPN). However, this term corresponds, more particularly, to an assembly of components, for example, the injection system. PID: Parameter Identifier This term, used in the J1587 standard, has an equivalent in the J1939 standard (SPN). However, this term corresponds, more particularly, to a specific component, for example, a sensor. PPID: Parameter Identifier This term, used in the J1587 standard, has an equivalent in the J1939 standard (SPN). PPID corresponds to PID, but is only used by VOLVO. FMI: Failure Mode identifier This represents the type of fault that has occurred. This may be an electrical, mechanical or equipment fault. VOLVO uses a SID-FMI or PID-FMI or PPID-FMI combination. Terminology used by PERKINS CID: Component parameter This term used by PERKINS has an equivalent in the J1939 standard (SPN). FMI: Failure Mode identifier This represents the type of fault that has occurred. This may be an electrical, mechanical or equipment fault. Terminology used by JOHN DEERE SPN: Suspect Parameter Number This represents the system or component at fault, for example: SPN 100, indicates an oil pressure problem or a problem with the oil pressure sensor. FMI: Failure Mode identifier This represents the type of fault that has occurred. This may be an electrical, mechanical or equipment fault. Terminology used by MTU Displaying faults The ADEC and MDEC general system faults are indicated on the equipment in the following way: fault code numbers (generated by the ECU - Engine control unit). 51/285 In the event of a fault, the screen will display the following message: FAULT ALARM ENGINE GENERAL 110 18 25/12/2005 15:30 OK=HELP Engine fault code. Pressing OK will display fault finding information. In addition, appendix D indicate the meaning of the code. The checking and maintenance operations to carry out in order to solve the fault are included in the user and maintenance manuals of the engines supplied with the generating set documentation. For JOHN DEERE (JD), PERKINS (PE) and VOLVO (VO) engines, the codes displayed are SPN and FMI codes. 6.2.4.5. Horn reset Depending on the settings made (menu 363 - HORN), the activation of an alarm and/or a fault leads to the horn sounding and the following screen appearing: HORN STOP PRESS OK 25/12/2005 This screen will display first any messages relating to the alarms and faults that appear as soon as OK is pressed. 15:30 52/285 6.3. Generator set with KERYS control panel 6.3.1 Presentation of the KERYS The MICS Kerys system consists of a set of electronic modules in which each module performs a specific function.. These modules are interconnected according to a very precise architecture and exchange data to allow the following: the command, control, regulation and protection of one or more generating sets according to multiple configurations. The configurations range from the so-called “solo” generating set, with or without source inverter, to generating sets coupled to each other, enabling electrical power plants to be created that can be coupled to one or more distribution grids in low voltage (LV) and medium voltage (MV). The MICS Kerys system consists of the following modules: • man/machine interface module, also called MMI module, • base module (heart of the system), • regulation module, • protection module, • logic input/output module, • analogue input/output module, • temperature input module. For the operation of a generating set in the smallest possible architecture, at least the following elements will be found: • a man/machine interface module, • a base module, • a regulation module. 6.3.1.1. Operating conditions Operating temperatures: - 20 °C + 70 °C Storage temperatures: - 20 °C + 70 °C Relative humidity during operation: 10 % to 95 % without condensation according to IEC 1131-2 and equivalent UL/CSA Relative humidity during storage: 5 % to 95% without condensation according to IEC 1131-2 and equivalent UL/CSA Height: 2,000 m during operation (Transfer 3,000 m) Degree of protection: - Outside cabinet: IP54 (front of MMI modules). - Inside cabinet: IP20 (BASE, ESTOR, ESANA, ETEMP, back of the MMI). Mechanical strength: Free falls (with packing), 5 random falls of: 1 m if p< 10 kg 0.5 m from 10 to 40 kg 0.25 m >40 kg 53/285 6.3.1.2. Conformity to legal and regulatory requirements The various components of the system comply with the following standards: Requirements specific to programmable controllers: (Functional characteristics, immunity, robustness, safety, etc.) EN 61131-1/2/3 (IEC 1131-2, IEC 664), EN61326, CSA 22-2, UL508. Compliance with European directives (low voltage, electromagnetic compatibility, machinery). CE marking in application of the safety requirements of standard EN 61131-2 – Programmable controllers, Part 2 – Equipment requirements and tests. To obtain the specific information prescribed by EN 61131-2, refer to the appropriate sections of that publication. Electrical and self-extinguishability properties of insulating materials: UL 746C, UL 94. Pollution degree: 2 Mechanical strength (details): Vibration resistance: EN 61131-2 1994 (§2.1.3.2), Frequency range: 10 - 57 Hz, Continuous vibrations: 0.0375mm amplitude, Occasional vibrations: 0.075mm amplitude. Frequency range: 57Hz - 150Hz, Continuous: 0.5 g constant acceleration, Occasional: 1 g constant acceleration. Complies with standard IEC 68-2-6, test Fc Shock resistance Occasional shocks: 15g, 11ms, semi-sinus. Complies with standard IEC 68-2-27, test Fa Emissions: Complies with standard EN55022 class A Variation in supply voltage: EN61131-2 §6.3.7.3 Immunity: Complies with standard IEC 61000-4-2: Complies with standard IEC 61000-4-3 Complies with standard IEC 61000-4-4: Complies with standard IEC 61000-4-5: Complies with standard IEC 61000-4-6: Complies with standard IEC 61000-4-8: Electrostatic discharge: 4 kV for contact discharge, 8 kV for air discharge. Radiated field at 10V/m from 80MHz to 1GHz with sinusoidal modulation AM 1kHz. Rapid transients in waves of 2 kV on power cables, 1 Kv on signal cables. Shock waves of 2 kV between wires and ground, 11 kV between wires for the supplies and 1kV relative to ground for long signal circuits (lines from a building or from a distance of over 30 m). Immunity to current injected at 3V from 150 kHz to 80 MHz (could be increased to 10V). Immunity to the magnetic field at the grid frequency at 30 A/m. 54/285 6.3.2 Description of the KERYS 6.3.2.1. Identification of the hardware components KERYS Tactil MMI module MMI Module P/N: 31613391001 D346000/B1 S/N: 1800 BATCH No.: 08/06 Module item reference D346000: manufacturer product reference B1: module hardware upgrade index 1800: serial number “not related” with a batch number (1800 = the 1800th module manufactured since the start) 08: year of manufacture (year 2008) 06: week of manufacture (week 6) Base module Base module P/N: 31613390901 D338000/B8 S/N: 3491 BATCH No.: 07/45 Module item reference D338000: manufacturer product reference B8: Module hardware upgrade index 3491: serial number “not related” with a batch number (3491 = the 3491st module manufactured since the start) 07: year of manufacture (year 2007) 45: week of manufacture (week 45) 55/285 Regulation module Regulation module 31613391501 Module item reference A44Z1: manufacturer product reference A44Z1-G G: “main” module hardware upgrade index 04: week of manufacture (week 4) 08: year of manufacture (year 2008) A: “secondary” module hardware upgrade index 0408A519 519: serial number “related” with a batch number (*) (519 = the 519th module manufactured in week 04 of the year 2008) (*) i.e. a maximum of 999 modules that can be related with a batch number. Protection module Protection module 31613391601 Module item reference A44Z2: manufacturer product reference A44Z2-E E : “main” module hardware upgrade index 43: week of manufacture (week 43) 07: year of manufacture (year 2007) A: “secondary” module hardware upgrade index 4307A035 035: serial number “related” with a batch number (*) (035 = the 35th module manufactured in week 04 of the year 2008) (*) i.e. a maximum of 999 modules that can be related with a batch number. 56/285 Logical inputs and outputs module Logical inputs and outputs module (ESTOR – Binary inputs and outputs) P/N : Module item reference 31613391201 D341000: manufacturer product reference D341000/B1 B1: module hardware upgrade index 0250: serial number “not related” with a batch number S/N: 0250 (0250 = le 250th module manufactured since the start) 06: year of manufacture (year 2006) Batch No.: 06/49 49: week of manufacture (week 49) Analogue inputs and outputs module Analogue inputs and outputs module (ESANA) P/N: Module item reference 31613391301 D343000: Manufacturer product reference D343000/B1 B1: module hardware upgrade index 0200: serial number “not related” with a batch number S/N: 0200 (0200 = the 200th module manufactured since the start) BATCH No.: 06: year of manufacture (year 2006) 06/49 49: week of manufacture (week 49) Temperature inputs module Temperature inputs module (ETEMP) P/N: Module item reference 31613391401 D344000: manufacturer product reference D344000/B1 B1: module hardware upgrade index 0150: serial number “not related” with a batch number S/N: 0150 th (0150 = the 150 module manufactured since the start) BATCH No.: 06: year of manufacture (year 2006) 06/49 49: week of manufacture (week 49) 57/285 6.3.2.2. Identification of the software components Only the components base module, MMI module, regulation module and protection module have embedded software. ”Software version” is referred to in order to identify a program implemented in one of the components. V: as software version 1.05 : is the revision, which is a combination of 3 digits c : main revision index 1 : secondary revision index used for specific projects Date of software version in English (year, month, day). V1.05c1 2007_02_12 For a modification of a software version during the life of one of the products (developments, corrections, etc.), the new software version implemented will be entered by hand in a space reserved for this. The old software version will then be deleted. factory soft version V1.05c 2007 02 12 Location of the version labels factory soft version V1.05c 2007 02 12 MMI factory soft version V1.05c 2007 02 12 Base module factory soft version V1.05c 2007 02 12 factory soft version V1.05c 2007 02 12 Regulation module Protection module 58/285 6.3.3 Description of the Man Machine Interface (IHM/MMI) 6.3.3.1. The Man Machine Interface Signalling control keys Operating buttons of the generating set Navigation keys Alphanumeric keypad Backlit display with touch-sensitive keypad Display The display has the following specifications: 7-inch colour TFT display, 16/9, 65536 colours dimensions: 154 mm x 86 mm neon backlighting 480 x 234 resolution touch panel (8 columns x 8 rows). 59/285 M.M.I. operation LED (flashing) The generating set operational keys 1 3 2 4 15 5 14 13 12 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 11 10 9 8 7 6 Manual mode selection. The illuminated led indicates that the mode is active Selecting stop mode. The illuminated led indicates that the mode is active Automatic mode selection. The illuminated led indicates that the mode is active Test in progress LED. In auto mode: test sequence control (off load test / load test) (*) In manual mode: engine start-up and stop Generating set circuit breaker opening control Led indicating that generating set circuit breaker is open Grid circuit breaker opening control Led indicating that grid circuit breaker is open Grid circuit breaker closing control Led indicating that grid circuit breaker is closed Led indicating the presence of grid voltage Led indicating that grid circuit breaker is closed Closing control for generating set circuit breaker Led indicating the presence of generating set voltage (*) The test request brings up a screen which offers a choice between “load test” and “off load test”. The signalling control keys The key clears the faults. The key stops the buzzer. The key commands testing of the LED’s on the front of the MMI. 60/285 The navigation keys It is also possible to navigate through the menus using the keypad. Return to upper level or escape for the dialogue boxes Move up Move to the right Move to the left Confirm function of selected key Move down It is possible to gain direct access to a menu by pressing the numerical key corresponding to its name. The alphanumeric keys They allow alphanumeric input by successive pressing of the keys. The characters entered appear in the order they were typed on the keypad. 61/285 6.3.3.2. Navigation in the screens There are three types: the home screen, the navigation screens, the operation and configuration screens. Home screen This screen is the entry point to the system. It enables the main functions of the navigation to be accessed. 15/10/03 19:10 :00 GS 1 Home Auto Faults -1Operation Alarms -6System -2Fault finding -5Configuration -4Maintenance -3Archiving/Metering Navigation screens These screens enable the various sub-menus to be accessed. Upper level 15/07/09 19:10 :00 Lower levels Title of the active menu GS 1 System Auto Faults Alarms -0Welcome -1Operation -2Function keys -7User adjustments -3Synchro. column -6Alarms & Faults -4Central measurements summary -5Measurements When a key is selected the lower level sub-menu appears if available or the allocated operation screen. A sub-menu can also be accessed by pressing the corresponding key. E.g.: by pressing key “1” on the alphanumeric keypad, you can directly access the "Operation” screen. 62/285 The operating and configuration screens These screens bring up the information and commands relating to the active menu. They are divided into three zones: an upper band common to all types of screens. the central section in which the specific information on the selected menu appears. a lower band. Upper band 15/07/09 19:10 :00 -1Electrical archive GS 1 Central section Event archive -2Mechanical archive Auto Faults Alarms -3 – Event metering Lower band Upper band Indications Indication of the presence of an alarm on the GS concerned (orange flashing) Date of the system Time of the system Reference of the GS with which the M.M.I. dialogues Indication of the presence of a fault on the GS concerned (flashing red) Indication of the operating mode of the GS concerned Name of the active screen 15/07/09 19:10 :00 GS 1 Welcome 63/285 Auto Faults Alarms Controls Access to the “Alarms and Faults” screen Access to the regional parameters screen Access to the “Alarms and Faults” screen Access to the “Drive” or “TOR variables” screen Access to the regional parameters screen 15/07/09 19:10 :00 GS 1 Welcome When configured in power plant with switches, displays a dialogue box enabling you to select the generating set to which you want to be connected Auto 1st action: 2nd action: Faults Alarms access to the home screen return to the menu previously selected (before first pressing the button) Lower band One or more shortcut keys to the functions associated with the active screen -1Function keys Return to the navigator menu Return to the last active operating screen -2Synchro. column -3– Measurements The registration dialogue box The registration dialogue boxes To facilitate the entry of the information (parameters, texts), there are special screens, called “dialogue boxes”, which appear when the need arises. Confirmation of an entry in a menu After the modification of a value in a menu the following dialogue box appears: Validation Validation of data entered Valid Esc. The confirmation key “Valid” saves the modification, the escape key “Esc.” cancels the modification. 64/285 Entry of a text Name of the modified function Text to be modified or created Inserts a space to the left of the cursor Title configuration CDE AERO Insert Valid Copy Delete title Paste Delete a character Esc. Deletes the letter shown by the cursor Deletes the entire text Closes the menu without saving the changes Saves the changes and closes the dialogue box You move within the text using the “right” or “left” arrows on the keypad. The characters are entered by means of the alphanumeric keys on the keypad. Entering numerical values The heading of the box provides information on the type of value entered, its unit and the variable concerned. These indications are linked to the type of modified parameter. If it exists, indicates the lowest possible value If it exists, indicates the highest possible value Time in 1/10 second (6000) 0<= 0000 Valid <=9999 Esc. Closes the screen without saving the modifications Saves the modifications and closes the screen 65/285 Selecting from a list The box heading indicates the parameter which will be assigned from your selection. Arrows for moving the cursor List indicating possible selections Type of fault (6000) Whithout General Alarm Valid Esc. Active selection Arrows only visible if the number of choices does not fit on the screen (enables you to go to the next page on the list or return to the previous page on the list) Saving changes After changing a parameter, the new data is stored in volatile memory, which means that in the event of a power failure, any changes will be lost. It is also necessary to transfer these values to permanent memory. This is the “Save in flash” operation. Following a modification a red “Sauvegarde à faire” (Save) indicator light flashes at the top left of the screen. Pressing this indicator light brings up one of the following dialogue boxes: Save in flash Valid Esc. Save in flash 3 Customer Factory Valid Esc. Always select “Client” Pressing “Valid” confirms the operation, pressing “Esc.” cancels it. 66/285 During saving, the following screen indicates that the operation in is progress: Saving in flash… 6.3.4 Configurations 6.3.4.1. Operating principle The operational modes are as follows: Without coupling to grid Without N/E switch (A612) - Operation of a single genset without coupling. - Normal/emergency switch (NES) not controlled by Kerys. With coupling to grid Temporary coupling (A651) - Automatic operation of a single genset. - Temporary coupling on grid return following interruption. Without N/E switch (A632) - Operation of a power plant without coupling to grid. - Normal/emergency switch (NES) not controlled by Kerys. - Power plant gensets interconnected by parallel lines. Without N/E switch (A633) - Operation of a power plant without coupling to grid. - Normal/ermegency switch (NES) not controlled by Kerys. - Power plant genset interconnected by CAN. SOLO Genset Power plant Without coupling to grid Note: Without coupling: the switch is equipped with electrical and mechanical interlocking. With coupling: the switch is not equipped with an electrical and mechanical interlock. 67/285 6.3.4.2. Legends M A Electrically controlled circuit breaker B Exchange of information from A to B and from B to A Transmission of information from A to B only 3 PH 3 PH + N 6.3.4.3. ”Current” information, 3 PH = 3 phases ”Voltage” information, 3 PH + N = 3 Phases + Neutral Configuration in solo generating set Without Normal/Emergency inverter (A612) This configuration is designed to provide: The generation of electricity for an installation from an external starting command (dry contact). The generation of electricity for an installation in forced operation. 3PH 3PH + N M CAN Bus Regulation module Ethernet Base module Application (load) MMI module Automatic operation (Kerys in “AUTO” mode) Loss of grid voltage • Generating set start request (dry contact, switch, clock, etc.). • The speed and voltage of the generating set increase. • Generating set power unit switched off after voltage and frequency stabilisation. Return of grid voltage • Dry contact, switch, clock, etc. switched on. • Cooling delay. • Generating set stopped and set to standby. 68/285 FORCED OPERATION (Kerys in “AUTO” mode) Start of FORCED OPERATION • Generating set start request (dry contact, switch, clock, etc.). • The speed and voltage of the generating set increase. • Generating set power unit switched off after voltage and frequency stabilisation. The installation is supplied by the generating set End of FORCED OPERATION • Dry contact, switch, clock, etc. switched on. • Generating set power unit switched on. • Cooling delay. • Generating set stopped and set to standby. The Kerys remains in ”AUTO” mode Manual operation of generating set This mode of operation is selected with the “MANU” key (on the front of the MMI module). The operator is able to start and stop the generating set by using the MMI keypad. The generating set power unit is switched off by means of the MMI keys. The safety devices of the generating set remain active in this mode of operation. This mode of operation is the responsibility of the operator. Temporary coupling to the grid (A651) This configuration is designed to provide: Emergency electricity supply to an installation following a grid loss. Return to the grid is achieved by a temporary coupling with transfer of the generating set load to the grid. FORCED OPERATION with a generating set. Temporary coupling for “Effacement Jour de Pointe” (EJP)* mode or other rates (Information transmitted by dry contacts). Grid 3PH 3PH + N M 3PH CAN bus Regulation module 3PH Ethernet Base module MMI Module M Optional manual or motorised circuit breaker M Application (load) * the “EJP” (Peak Day Load Shedding) system is specific to the French power grid. 69/285 Automatic operation (Kerys in “AUTO” mode) (temporary “grid return” coupling) Loss of grid voltage • Adjustable grid loss acquisition delay (controlled by the Kerys or by a mains detection module). • Generating set start request. • The speed and voltage of the generating set increase. • Power unit switched on, grid side. • Generating set power unit switched off after voltage and frequency stabilisation. Return of grid voltage • Adjustable grid return acquisition delay (controlled by the Kerys or by a mains detection module). • Synchronisation of the generating set to the grid. • After synchronisation, the grid power unit is switched off. • Transfer of the active and reactive power of the generating set to the grid according to a predetermined ramp. The ramp does not exceed 10 seconds for transfer of the generating set’s rated output. The generating set power unit is disconnected when the power on the generating set reaches the lower limit. • Generating set power unit switched on. • Cooling delay. • Generating set stopped and set to standby. The Kerys remains in “AUTO” mode FORCED OPERATION (Kerys in “AUTO” mode) (temporary outward and return coupling) Start of FORCED OPERATION • Generating set start request. • The generating set voltage and speed increase. • When the generating set is stabilised in speed and voltage, synchronisation of the generating set to the grid is requested. • After synchronisation, the generating set power unit is switched off. • Transfer of the active and reactive power from the grid to the generating set according to a predetermined ramp. The ramp does not exceed 10 seconds for transfer of the generating set’s rated output. The generating set power unit is disconnected when the power on the generating set reaches the lower limit. • Power unit switched on, grid side. The installation is supplied by the generating set End of FORCED OPERATION • Opening of the forced operation order. • Synchronisation of the generating set to the grid. • Grid power unit switched off. • Transfer of the generating set’s active and reactive power to the grid. • Generating set power unit switched on. • Cooling delay. • Generating set stopped and set to standby. The Kerys remains in “AUTO” mode The installation is supplied by the grid Manual generating set operation This mode of operation is selected with the “MANU” key. The operator is able to start and stop the generating set via the MMI keypad. The power unit is switched off manually with the manual synchronisation of the generating set to the grid using the keys “+ F”, “- F”, “+V”, “-V”, the load transfer remains automatic. The safety devices of the generating set remain active in this mode of operation. This mode of operation is the responsibility of the operator 70/285 6.3.4.4. Power plant configuration (Several generating sets in parallel) Without common part and without Normal/Emergency inverter (A632) This configuration is designed to provide: Emergency electricity supply to an installation following a grid loss (The grid loss is not controlled by Kerys). Return to the grid will be achieved by Normal / Emergency switchover by means of a self-driven inverter (not controlled by Kerys). FORCED OPERATION with a generating set. Operation in “Effacement Jour de Pointe” (EJP)* mode or other rates.(Information transmitted by dry contacts). An active power regulation (speed of the generating sets) by parallel lines connected between all the regulation modules. Genset 2 Genset 1 3PH 3PH Parallel line CAN bus Base module Base module Ethernet M 3PH 3PH 3PH + N M Ethernet 3PH + N Regulation module CAN bus Regulation module Genset x (*) the “EJP” (Peak Day Load Shedding) system is specific to the French power grid. Note 1: In this operating mode there is no reactive power regulation (generating set voltage); the generating sets are static. Note 2: In an installation of the power station type (several generating sets in parallel) two modes of coupling between generating sets are possible • Coupling when stopped. • Coupling in normal operation. Principle of coupling when stopped - all the generating set power units are switched off, - starting of all the generating sets, - when the speed reaches 1450 rpm, activated excitation command on all the generating sets, - the voltage generated by each generating set increases gradually and the voltage is therefore the same in all generating sets, - the generating sets therefore reach 1500 rpm at 400 V 50 Hz. At the end of global operation, if the power consumed by the installation does not require the operation of all the generating sets within the power plant, one or more generating sets will be stopped according to the wattmetric control. Restarting of the generating set (these generating sets) depends on the load and wattmetric control of the load. However, if a generating set is reconnected to a busbar already subjected to a load, the “recoupling” is carried out in normal operation and not when the generating set is stopped. 71/285 Principle of coupling in normal operation Coupling in normal operation enables all the generating sets to be coupled (in voltage and frequency) to a busbar supplied by a generating set designed as master at the output. A number (1 to 15) is assigned to each Kerys. This number serves solely to establish the IP address of each Kerys for communication by Ethernet and loading the programs. A second number (from 1 to 15) is also assigned to each Kerys and defines the priority. Example: let us assume a plant of 8 generating sets Gen set 1 2 3 4 5 6 7 8 Priority 08 07 06 05 04 03 02 01 The numbers on the first line enable the IP address of each Kerys to be allocated. The numbers on the second line define the priority. Therefore Kerys no. 8 with priority 01 is considered to be the master generating set and closes its flow first. The other generating sets then synchronise one by one to the central busbar, transmitting the information on voltage, frequency and phase difference to this busbar (see sketch). GS2 GS1 GS3 U2 U1 CB2 CB1 U3 CB3 Busbar U Example for 3 GSs: • DJ1 (Circuit breaker 1) is closed, the voltage is present on the busbar. • Kerys 2 analyses the differences between U2 and U of the busbar before coupling. • Kerys 3 analyses the differences between U3 and U of the busbar before coupling. Each Kerys, independently of its neighbour, will close its discharge on the central busbar. Wattmetric control The wattmetric control is used when two generating sets are coupled. It provides optimum management of the number of generating sets operating by constantly analysing the power required by the user. Let us take the example of a power plant of 4 x 600 kW generating sets. The threshold setting screen (1-7-3-3) supplies the following data: Threshold 1 GS => 2 GS 75% 450 kW Threshold 2 GS => 1 GS 30 % 360 kW Threshold 2 GS => 3 GS 75% 900 kW Threshold 3 GS => 2 GS 30 % 540 kW Threshold 3 GS => 4 GS 75% 1350 kW Threshold 4 GS => 3 GS 30 % 720 kW The maximum available power is 600 x 4 = 2400 kW. Assuming that a single generating set is operating, we will have the following sequence in the case of linear progression of the load. When the power required by the application reaches 75% of the power of the generating set in operation (GS at priority 01), i.e. 450 kW, the second GS (at priority 02) is started and is synchronised with GS 1. Its flow is then closed. 72/285 The second GS thus coupled initiates its power on ramp (adjustable delay) and the distribution of power among the two generating sets takes place. Each generating set will then take 50% of the required power, i.e. 225 kW. When the power required for the application reaches 75% of the power of the two generating sets in operation (GSs at priority 01 and 02), i.e. 900 kW, the third GS (at priority 03) is then started and is synchronised with GS1 and GS2. Its flow is then closed. The third GS thus coupled initiates its power on ramp (adjustable delay), and the distribution of power among the three generating sets takes place. Each generating set will then take 33.33% of the required power, i.e. 300 kW, corresponding to 50% of its rated output (600 kW). When the power required for the application reaches 75% of the power of the three GSs in operation (GSs at priority 01, 02 and 03), i.e. 1350 kW, the fourth GS (at priority 04) is then started and synchronised with GS1, GS2 and GS3. Its flow is then closed. The fourth GS thus coupled initiates its power on ramp (adjustable delay) and the distribution of power among the four generating sets takes place. Each generating set will then take 25% of the power required, i.e. 337.5 kW, corresponding to 56.25% of its rated output (600 kW). The power required for the application may continue to increase up to the upper plant limit (95%) of 2400 kW, i.e. 2280 kW (the setting can be changed). This corresponds of course to the upper generating set limit, i.e. 570 kW (95% of 600 kW). Automatic operation (All Kerys PLCs in “AUTO” mode) (coupling when stopped) Loss of grid voltage • Grid loss acquisition delay (controlled by the mains detection module). • Generating set power units switched off. • Generating set start request. • The generating sets’ speed increases. • Speed stabilisation delay. • Order of excitation for each generating set at nominal speed; the voltage is then quickly established on the busbar. • Start of distribution of active power. • Resumption of use at the rated power and frequency. Wattmetric control This wattmetric control will be activated after a global operation delay. This global operation enables the application to be resumed after power is restored to the different outputs, and ensures stability of the load before the wattmetric control is started. Depending on the power for the application, the number of generating sets in production may vary in order to optimise the production for consumption. The procedure is as follows: • End of the global operation delay. • Start of analysis of the active power consumed. Example: A generating set must be stopped according to the set thresholds. • Power cut at the non-priority generating set, transfer of the power to the generating set(s) remaining in production. • Uncoupling of the non-priority generating set, at zero power, by switching on the generating set power unit. • Cooling delay. • Generating set stopped and set to standby. Example of increase in power: • Generating set start request. • The speed of the generating set increases. • Alternator excitation, the generating set establishes its voltage. • Request for synchronisation of the generating set to the busbar (i.e. the other coupled generating sets). • Generating set power unit switched off. Return of grid voltage • Grid return acquisition delay (controlled by the mains detection module). • Generating set power units switched on. • Cooling delay. • Generating sets stopped and set to standby. The Kerys PLCs remain in “AUTO” mode 73/285 FORCED OPERATION Start of FORCED OPERATION • Generating set power units switched off. • Generating set start request. • The generating sets increase in speed. • Speed stabilisation delay. • Order of excitation for each generating set at nominal speed; the voltage is then quickly established on the busbar. • Start of active power distribution. • Resumption of application at rated voltage and frequency. The Kerys PLCs remain in “AUTO” mode The installation is supplied by the generating sets End of FORCED OPERATION • Generating set power units switched on. • Cooling delay. • Generating sets stopped and set to standby. The Kerys PLCs remain in “AUTO” mode The installation is supplied by the grid Manual power plant operation This mode of operation is selected with the “MANU” key. This enables the operator to start and stop the generating sets one by one via the MMI keypad. The generating set power unit is switched off manually with synchronisation of each generating set to the busbar using the MMI keys “+F”, “-F”, “+V” and “-V”. The distribution of power among the generating sets remains automatic. The safety devices of the generating sets remain active in this mode of operation. This mode of operation is the responsibility of the operator. Without common part and without Normal/Emergency inverter (A633) This configuration is designed to provide: Emergency electricity supply to an installation following a grid loss (The grid loss is not controlled by the Kerys). Return to the grid can be achieved via Normal / Emergency switchover with a self-driven inverter (not controlled by the Kerys). FORCED OPERATION with a generating set. Operation in “Effacement Jour de Pointe” (EJP)* mode or other rates. (Information transmitted by dry contacts). Active power regulation (speed of the generating sets) by digital buses connected between all the regulation modules. Genset 2 Genset 1 3PH 3PH Digital Bus Base module Ethernet M CAN bus Digital Bus 3PH 3PH Base module 3PH + N M Ethernet 3PH + N Regulation module CAN bus Regulation module Genset x (*) the “EJP” system is specific to the French power grid. Note 1: In this operating mode active and reactive power is distributed by a digital bus between the regulation modules (voltage of the generating sets). Note 2: In an installation of the power plant type (several generating sets connected by digital bus), two modes of coupling between generating sets are possible • Coupling when stopped. • Coupling in normal operation. 74/285 Principle of coupling when stopped - all the generating set power units are switched off, - starting of all the generating sets, - when the speed reaches 1450 rpm, activated excitation command on all the generating sets, - the voltage generated by each generating set increases gradually and the voltage is therefore the same in all generating sets, - the generating sets therefore reach 1500 rpm at 400 V 50 Hz. At the end of global operation, if the power consumed by the installation does not require the operation of all the generating sets within the power plant, one or more generating sets will be stopped according to the wattmetric control. Restarting of the generating set (these generating sets) depends on the load and wattmetric control of the load. However, if a generating set is reconnected to a busbar already subjected to a load, the “recoupling” is carried out in normal operation and not when the generating set is stopped. Principle of coupling in normal operation Coupling in normal operation enables all the generating sets to be coupled (in voltage and frequency) to a busbar supplied by a generating set designed as master at the output. A number (1 to 15) is assigned to each Kerys. This number serves solely to establish the IP address of each Kerys for communication by Ethernet and loading the programs. A second number (from 1 to 15) is also assigned to each Kerys and defines the priority. Example: let us assume a plant of 8 generating sets Gen set 1 2 3 4 5 6 7 8 Priority 08 07 06 05 04 03 02 01 The numbers on the first line enable the IP address of each Kerys to be allocated. The numbers on the second line define the priority.Therefore Kerys no. 8 with priority 01 is considered to be the master generating set and closes its flow first. The other generating sets then synchronise one by one to the central busbar, transmitting the information on voltage, frequency and phase difference to this busbar (see sketch). GS2 GS1 U2 U1 CB1 GS3 CB2 U3 CB3 Busbar U Example for 3 GSs: • DJ1 (Circuit breaker 1) is closed, the voltage is present on the busbar. • Kerys 2 analyses the differences between U2 and U of the busbar before coupling. • Kerys 3 analyses the differences between U3 and U of the busbar before coupling. Each Kerys, independently of its neighbour, will close its discharge on the central busbar. 75/285 Wattmetric control The wattmetric control is used when two generating sets are coupled. It provides optimum management of the number of generating sets operating by constantly analysing the power required by the user. Let us take the example of a power plant of 4 x 600 kW generating sets. The threshold setting screen (1-7-3-3) supplies the following data: Threshold 1 GS => 2 GS 75% 450 kW Threshold 2 GS => 1 GS 30 % 360 kW Threshold 2 GS => 3 GS 75% 900 kW Threshold 3 GS => 2 GS 30 % 540 kW Threshold 3 GS => 4 GS 75% 1350 kW Threshold 4 GS => 3 GS 30 % 720 kW The maximum available power is 600 x 4 = 2400 kW. Assuming that a single generating set is operating, we will have the following sequence in the case of linear progression of the load. When the power required by the application reaches 75% of the power of the generating set in operation (GS at priority 01), i.e. 450 kW, the second GS (at priority 02) is started and is synchronised with GS 1. Its flow is then closed. The second GS thus coupled initiates its power on ramp (adjustable delay) and the distribution of power among the two generating sets takes place. Each generating set will then take 50% of the required power, i.e. 225 kW. When the power required for the application reaches 75% of the power of the two generating sets in operation (GSs at priority 01 and 02), i.e. 900 kW, the third GS (at priority 03) is then started and is synchronised with GS1 and GS2. Its flow is then closed. The third GS thus coupled initiates its power on ramp (adjustable delay), and the distribution of power among the three generating sets takes place.Each generating set will then take 33.33% of the required power, i.e. 300 kW, corresponding to 50% of its rated output (600 kW). When the power required for the application reaches 75% of the power of the three GSs in operation (GSs at priority 01, 02 and 03), i.e. 1350 kW, the fourth GS (at priority 04) is then started and synchronised with GS1, GS2 and GS3. Its flow is then closed. The fourth GS thus coupled initiates its power on ramp (adjustable delay) and the distribution of power among the four generating sets takes place. Each generating set will then take 25% of the power required, i.e. 337.5 kW, corresponding to 56.25% of its rated output (600 kW). The power required for the application may continue to increase up to the upper plant limit (95%) of 2400 kW, i.e. 2280 kW (the setting can be changed).This corresponds of course to the upper generating set limit, i.e. 570 kW (95% of 600 kW). Automatic operation (All Kerys PLCs in “AUTO” mode) (coupling when stopped) Loss of grid voltage • Grid loss acquisition delay (controlled by the mains detection module). • Generating set power units switched off. • Generating set start request. • The generating sets increase in speed. • Speed stabilisation delay. • Order of excitation for each generating set at nominal speed; the voltage is then quickly established on the busbar. • Start of active power distribution. • Resumption of application at rated voltage and frequency. 76/285 Wattmetric control This wattmetric control will be activated after a global operation delay. This global operation enables the application to be resumed after power is restored to the different outputs, and ensures stability of the load before the wattmetric control is started. Depending on the power for the application, the number of generating sets in production may vary in order to optimise the production to consumption. The procedure is as follows: • End of the global operation delay. • Start of analysis of the active power consumed. Example: A generating set must be stopped according to the set thresholds. • Power cut at the non-priority generating set, transfer of the power to the generating set(s) remaining in production. • Uncoupling of the non-priority generating set, at zero power, by switching on the generating set power unit. • Cooling delay. • Generating set stopped and set to standby. Example of increase in power: • Generating set start request. • The generating set increases in speed. • Alternator excitation, the generating set establishes its voltage. • Request for synchronisation of the generating set to the bus bar (i.e. the other coupled generating sets). • Generating set power unit switched off. Return of grid voltage • Grid return acquisition delay (controlled by the mains detection module). • Generating set power units switched on. • Cooling delay. • Generating sets stopped and set to standby. The Kerys PLCs remain in “AUTO” mode FORCED OPERATION Start of FORCED OPERATION • Generating set power units switched off. • Generating set start request. • The generating sets increase in speed. • Speed stabilisation delay. • Order of excitation for each generating set at nominal speed; the voltage is then quickly established on the busbar. • Start of active power distribution. • Resumption of application at rated voltage and frequency. The Kerys PLCs remain in “AUTO” mode The installation is supplied by the generating sets End of FORCED OPERATION • Generating set power units switched on. • Cooling delay. • Generating sets stopped and set to standby. The Kerys PLCs remain in “AUTO” mode The installation is supplied by the grid Manual power plant operation This mode of operation is selected with the “MANU” key. This enables the operator to start and stop the generating sets one by one via the MMI keypad. The generating set power unit is switched off manually with synchronisation of each generating set to the busbar using the MMI keys “+F”, “-F”, “+V” and “-V”. The distribution of power among the generating sets remains automatic. The safety devices of the generating sets remain active in this mode of operation. This mode of operation is the responsibility of the operator. 77/285 6.3.5 Connections of the generating sets 6.3.5.1. Recommendations before the connections Disconnect the battery cables before carrying out any work on the generating set. To disconnect the battery disconnect the negative cable (-) first. Warning Ground connection X Facility power outlet O O X X O O Connecting cables between the generating sets (CAN BUS) X Connecting cables between the generating sets (Parallel line) Power cables Power plant without common part and without inverter (A633) X Ground connection box Power plant without common part without inverter (A632) Solo generating set, CRF coupling (A651) Connections according to the configurations Solo generating set without inverter (A612) 6.3.5.2. X X X X X Remote operation z z z z External emergency stop z z z z EJP z z z z Switch grid detection (1) z z z Grid detection by regulation card (1) z z z Customer terminal: Emergency N/E switch control z Emergency cutout z Normal N/E switch control X: to be connected (1) X z Summary of faults and alarms z z z z Generating set operation z z z z Generating set available in Auto z z z z O: if available z: if necessary Only one of the two grid detections needs to be cabled. 78/285 6.3.5.3. • Earthing system (Standard only) The ground of the generating set must be connected to earth. To do so, use a copper cable (Green / Yellow), 25 mm² minimum for a bare cable and 16 mm² for an insulated cable, connected to the earth of the generating set, and to a ground rod of galvanised steel pushed vertically into the ground. For a fault voltage of 25 V and a fault current of 30 mA. Rod length (in metres) Nature of the ground Rich arable land, moist compact hard core Poor arable land Poor arable land, gravel, coarse hard core Stony bare soils, impermeable rocks dry 1 1 1 sand, To obtain an equivalent length several ground rods can be used connected in parallel and separated by at least their length. Example: Four 1 metre rods interconnected and separated by 1 metre respectively. 3.6 • Check the earthing connection before switching on the generating set. • Check that the safety earthing system is working. Single genset Earthing system: IT Active isolation controller Interconnection bar between genset grounds Isolated neutral CIRCUIT DISJONCTEUR BREAKER Current transformer Ground N Ground rod 79/285 R S T Earthing system: TNS Interconnection bar between genset grounds Neutral connected to grounds CIRCUIT DISJONCTEUR Current transformer BREAKER Ground N R S T Ground rod Earthing system: TT Active differential circuit breaker Interconnection bar between genset grounds Neutral CIRCUIT BREAKER DISJONCTEUR Current transformer Ground N R S T Ground rod Type of earthing system: EDF application (On rental generating set only) Active differential circuit breaker Interconnection bar between genset grounds Neutral CIRCUIT BREAKER DISJONCTEUR Current transformer Ground N R S Ground rod 80/285 T Power plant Connection of the generating sets to the box Genset 2 Genset x Neutral GSX current transformer link GS2 current transformer link GS1 current transformer link Genset 1 1 current transformer per GS Earth junction box Ground rod Genset 1 Genset 2 One ground rod for one generating set power plant Important 81/285 Genset x Earthing system: IT Isolated neutral CIRCUIT DISJONCTEUR BREAKER Current transformer Ground R N S T Ground rod Earthing system: TNS Neutral connected to grounds CIRCUIT DISJONCTEUR Current transformer BREAKER Ground R N S T Ground rod Earthing system: TT Neutral CIRCUIT Current transformer Ground DISJONCTEUR BREAKER N R S T If equipped Ground rod Junction box 82/285 7 Xcbc3 Xcbc3 Connection of generating sets to client terminal boards 28 30 32 34 36 38 40 42 44 46 48 29 31 33 35 37 39 41 43 45 47 7 28 30 32 34 36 38 40 42 44 46 48 29 31 33 35 37 39 41 43 45 47 Junction box Remove the shunts at terminals 45-48 and 46-47 Reinsert the shunts of terminals 45 and 46 after having disconnected the current transformer from the junction box. Important 6.3.5.4. Facility power outlet The facility power outlet (if fitted) provides the emergency supply to the generating set from an external electrical source. It enables the different units (preheating, desk, etc.) to be powered without using their batteries. 83/285 6.3.5.5. Connecting cable between the generating sets (power plant) 2 generating sets Generating set 1 Generating set 2 019x04 019x04 019x12 019x12 3 or more generating sets Generating set 1 Generating set 2 Generating set 3 Generating set x 019x04 019x04 019x04 019x04 019x12 019x12 019x12 019x12 Connecting cable The power cables and the generating set connecting cable may intersect Power cable Important Connecting cable Rental application The generating set power cables and connecting cable cannot be placed in parallel less than 1 metre apart. 1 metre MIN. Power cable Important The generating set power cables, the generating set connecting cable and the connections must be in perfect condition. Replace them if necessary. Important 84/285 6.3.5.6. Power 1. Pass the power cables through the access hatch to the power box of the generating set (AIPR or console, depending on the generating set). 2. Connect the power cables to the busbars. 3. Connect the power cables to the application. N GENERATING SET R APPLICATION S T N R S T Check that the direction of rotation of the phases between the generating set and the application is the same. Important Type of cables: 6.3.5.7. Use H074NF type cables according to the standards in force in the country of use of the generating set (In France refer to the standard C15.100). Client terminal block Refer to the wiring diagrams according to the configuration selected and the requirements. 85/285 6.3.6 Operation and setting menus 6.3.6.1. Layout of the menus The diagram below shows the layout of the main menus. -0Home -1Operation -2Fault finding -3Archiving & Metering -4Maintenance -5Configurations -6System - 1.1 Operation - 2.1 Digital Variables - 3.1 Events archives - 4.1 Provider - 5.1 Equipment - 6.1 Regional parameters - 1.2 Function keys - 2.2 Analog variables - 3.2 Electrical archives - 4.2 Emails - 5.2 Applications - 6.2 Application identification - 1.3 Synchro. Column - 2.3 REG & PRO variables - 3.3 Mechanical archives - 4.3 Service intervals - 5.3 Regulations - 6.3 Software versions - 1.4 Power plant measurements synthesis - 2.4 Curves - 3.4 Events metering - 4.4 Consumables - 5.4 Safety features - 6.4 Printing - 1.5 Measurements - 2.5 Electrical faults - 3.5 Mechanical metering - 4.5 Progress reports - 6.5 Access management - 1.6 Alarms & faults - 2.6 Help - 3.6 Electrical metering - 4.6 Reports - 6.6 Web access management - 1.7 User settings - 2.7 Regulation mode display - 6.7 Factory Only the menu functions on a white background are described in this manual. Important 86/285 6.3.6.2. Setting of regional parameters Without an input access code this screen allows: input of the display language setting of date and time Navigation reference: 6.1 15/07/09 19 :10 :00 GS 1 Regional parameters Stop Faults Français English Espanol Deutsch Portugues Language option Day Month Year hours Minutes Seconds 22 10 07 17 10 00 Alarms Inhibit the keys -1– Identification application -2Software versions -3Printing To clean the touch screen (dust, hydrocarbons, etc.) the key inhibition function prevents keys on the screen from being pressed for some twenty seconds. A special screen shows the time elapsing. 87/285 When an access code of a sufficient level is validated this screen also allows: Setting of the module synchronisation time Selection of the logo displayed on the Kerys home screen. When the time setting by the SNTP protocol is not active the screen looks like this. 15/07/09 19 :10 :00 GS 1 Regional parameters Stop Faults Français English Espanol Deutsch Portugues Language option Day Month Year hours Minutes Seconds 22 10 07 17 10 00 Inhibit the keys SDMO welcome logo KOHLER welcome logo -1Identification application -2Software versions -3Printing Alarms In this case the transmission of a signal to the bus, enabling the different real time clocks to be reset, is defined by the synchronisation time. Pressing the “KOHLER home logo” key alters the appearance of the home screen by replacing the KOHLER logo with the SDMO logo as default. The home screen then looks like this: 15/07/09 19 :10 :00 GS 1 Welcome Auto Faults -1Operation Alarms -6System -2Fault finding -5Configuration -4Maintenance -3Archiving/Metering 88/285 In the second case the screen has this appearance. 15/07/09 6.3.6.3. 19 :10 :00 GS 1 Regional parameters Stop Faults Français English Espanol Deutsch Portugues Language option Day Month Year hours Minutes Seconds 22 10 07 17 10 00 Inhibit the keys SDMO welcome logo KOHLER welcome logo -1Identification application -2Software versions -3Printing Alarms Information on the KERYS Indication of the application Navigation reference: 6.2 This screen enables SDMO to identify the project. This information is required for queries sent to SDMO’s customer service, so that the associated file can be consulted. 15/07/09 19 :10 :00 Identification application GS 1 Stop Faults Site name Dealership number 000000 OM number 000000 Connection number 000000 -1Software versions -2Printing -3Access management Project number: reference of the production file for the control equipment. OM number: reference of the production file for the generating set. Connection number: reference used to identify the site at the time of the telephone connection. 89/285 Alarms Software version Navigation reference: 6.3 The information relating to the software versions installed in the different modules is accessible from this menu. Only the lines corresponding to the installed equipment appear 15/07/09 19 :10 :00 GS 1 Software versions Stop Faults Module Software versions Software version dates IHM 0.00 00/00/00 Base 0.00 00/00/00 Resident logic 0.00 00/00/00 Regulation 0.00 Protection 0.00 Engine 0.00 -1Identification application -2Printing -3Access management 90/285 Alarms 6.3.6.4. Operating menus Operation This main screen displays all the main electrical parameters of the generating set. It is the general operating and monitoring screen for the generating set. This screen can also be displayed by pressing the indicator displaying the operation mode of the generating set. The frequency, U23 voltage, active and reactive power indicators, can be displayed in analog or digital form. Switching from one mode to another is performed by pressing the desired indicator. Navigation reference: 1.1 15/07/09 19:10 :00 GS 1 I1 (A) Operation 2701 Manu P.F. Faults Alarms 0,9 L Status messages Q (kVAr) Speed (rpm) 1505 Operating time: 10 :05 +F -1Function keys -F +U 765 -U -3Central unit measure. summary -2Synchro. column Commande Control of alternator de la tension voltage de l’alternateur Control of speed Commande de laof vitesse rotation deof rotation the engine du moteur Indication of dethe la position genset output du départ position groupe The dial is automatically scaled beyond 46Hz In the needle dials the nominal values are in blue The speed and voltage adjustment keys are only displayed for coupled applications in manual mode. Important Alarms and faults This menu can also be called directly by pressing the flashing “Alarms” and “Faults” keys on the upper band. This screen allows the user to view the list of faults present on the installation. The first two columns give details of the date and time that the fault appeared. The “Status” column indicates whether the fault is still present “1”, or not present “0”. The “@” column gives the address of the variable associated with the fault. The “Text” column identifies the type of fault. A line with a red background characterises a fault and a line with an orange background characterises an alarm. 91/285 Navigation reference: 1.6 15/07/09 19 :10 :00 GS 1 Date Time Status @ Title 26/11/03 11:11:12’55 1 6131 HT LOW COOLANT LEVEL FAULT 26/11/03 10:35:16’28 0 6017 INSULATION 1 ALARM 26/11/03 10:10:10’10 0 60C3 CIRCUIT BREAKER FAULT ON GENERATING SET OUTPUT -1Function keys Active line Alarms & Faults -2Synchro. column Stop Faults Alarms -3Central unit measure. summary Keys for scrolling when the list is longer than the number of lines possible on the screen, i.e. 4 lines To clear a fault, it is necessary to: check that the fault has disappeared (status 0) and whether it is necessary to eliminate its causes select the line in question; the text on the line is displayed in white press the “Reset” key on the keypad; the line is deleted. When a fault is displayed, its effect on the operation remains active even if its cause has disappeared. When in Manu or Auto mode, if the user wants to clear a fault with a "stopped" clearance mode, a screen will inform the user to switch to stop mode. Important 92/285 6.3.7 Rental configurations 6.3.7.1. Choice of application configuration Solo generating set Without inverter (A612) 1. Turn off the battery isolator switch. 2. Check that the emergency stop buttons are activated. 3. Press the “STOP” button on the KERYS. 4. Turn the changeover switch to position 1. 1: SOLO GENERATING SET WITHOUT GRID COUPLING APPLICATION: A612 1 2: PRODUCTION POWER PLANT WITHOUT GRID COUPLING APPLICATION: A632 / A633 2 4 3: NOT APPLICABLE 4 : SOLO GENERATING SET WITH GRID COUPLING APPLICATION: A651 3 (If the switch is already set to “1”, turn the switch and return to position ‘’1’’) After changeover, the screen below appears. 15/07/09 19:10 :00 GS 1 Rental application A612: Single Genset without N/E Mains supply detection using the adjustment card Validation Mains supply detection using an external contact 93/285 Stop Faults Alarms 5. Select the configuration of the mains detection of the generating set by clicking directly on the touch screen. For a mains detection by means of the regulation card you must select the configuration “Mains supply detection using the adjustment card” and connect the voltage reference to the terminals Xcbc1 - 1-2-3. For mains detection by an external switch you must select the configuration “Mains supply detection using an external contact” and connect the external switch to the terminals Xcbc3 - 34-35. For starting by means of an external switch you must select the configuration “Mains supply detection using an external contact” and connect the external switch to the terminals Xcbc3 - 32-33. For solo starting, in the absence of a mains connection, you must select the configuration “Mains supply detection using an external contact”. No connection is necessary. N.B. selecting detection depends on the connection made according to Section “Connections of the generating sets”. Important 15/07/09 19:10 :00 GS 1 Rental application A612: Single Genset without N/E Mains supply detection using the adjustment card Validation Mains supply detection using an external contact 6. Press “Validation" on the touch screen. 94/285 Stop Faults Alarms Back-up to perform GS 1 Rental application Stop Faults Alarms A612: Single Genset without N/E Mains supply detection using the adjustment card Validation … Saving in flash Mains supply detection using an external contact 7. The KERYS saves your new configuration. 8. After return to the KERYS home screen, The configuration will only be taken into account if the following operations are carried out: Turn on the battery isolator switch. Wait 5 seconds. Turn off the battery isolator switch. Important Solo generating set, CRF coupling (A651) 1. Turn off the battery isolator switch. 2. Check that the emergency stop buttons are activated. 3. Press the “STOP” button of the KERYS. 4. Turn the changeover switch to position 4. 1: SOLO GENERATING SET WITHOUT GRID COUPLING APPLICATION: A612 1 2: PRODUCTION POWER PLANT WITHOUT GRID COUPLING APPLICATION: A632 / A633 2 4 3: NOT APPLICABLE 4 : SOLO GENERATING SET WITH GRID COUPLING APPLICATION: A651 3 (If the switch is already set to “4”, turn the switch and return to position ‘’4’’) 95/285 After changeover, the screen below appears. 15/07/09 19:10 :00 GS 1 Rental application Stop Faults Alarms A651: Temporary power grid single Genset coupling Validation Grid CT ratio 20.0 5. To enter the value of the grid current transformer ratio: press the “GRID CT RATIO” button on the touch screen. Using the alphanumeric keys of the MICS KERYS: enter the value of the CT ratio in tenths. Example: CT = 100A/5A (calculation: 100/5 =20; 20x10=200) value to be entered 200. CT BUSBAR/Grid setting 1 (1/10) 0<= 0200 Valid <=32767 Esc. 6. Then press “VALID” . 96/285 15/07/09 19:10 :00 GS 1 Rental application Stop Faults Alarms Stop Faults Alarms A651: Temporary power grid single Genset coupling Validation Grid CT ratio 20.0 7. Press the “Validation” button on the touch screen. 15/07/09 19:10 :00 GS 1 Rental application A651: Temporary power grid single Genset coupling Saving in flash … Validation Grid CT ratio 20.0 8. The KERYS saves your new configuration. 97/285 9. After return to the KERYS home screen, The configuration will only be taken into account if the following operations are carried out: Turn on the battery isolator switch. Wait 5 seconds. Turn off the battery isolator switch. Important Power plant Without common part and without inverter (A632-A633) 1. Turn off the battery isolator switch. 2. Check that the emergency stop buttons are activated. 3. Press the “STOP” button on the KERYS. 4. Turn the changeover switch to position 2. 1: SOLO GENERATING SET WITHOUT GRID COUPLING APPLICATION: A612 1 2: PRODUCTION POWER PLANT WITHOUT GRID COUPLING APPLICATION: A632 / A633 2 4 3: NOT APPLICABLE 4 : SOLO GENERATING SET WITH GRID COUPLING APPLICATION: A651 3 (If the switch is already set to “2”, turn the switch and return to position ‘’2’’) After changeover, the screen below appears. Choix configuration centrale loueur A632: Power plant without shared switching unit without Normal/Emergency parallel line A633: Power plant without shared switching unit without Normal/Emergency Digital Bus 5. Select the configuration “A632: Power plant without shared switching unit without Normal/Emergency parallel line” by directly clicking on the touch screen. Select the configuration “A633: Power plant without shared switching unit without Normal/Emergency Digital Bus” by clicking directly on the touch screen. N.B. selecting detection depends on the connection made according to Section 5. “Connections of the generating sets”. Important 98/285 Back-up to perform GS 1 Rental application Stop Faults Alarms Stop Faults Alarms A633: Power plant without shared switching unit without Normal/Emergency Digital Bus Number of gen sets in power plant 2 Genset number 1 Validation 6. Press the generating set number on the touch screen. Back-up to perform GS 1 Rental application A633: Power plant without shared switching unit without Normal/Emergency Digital Bus Number of gen sets in power plant 2 Number of gen sets in power plant Genset number 1 0<= Validation<=15 02 Valid Esc. 7. Enter the number of generating sets in Start with “0” if the number E.g.: 2 generating sets enter 0 then 2; 10 generating sets the power is less enter 1 then 0. 8. Press “Valid” to confirm the entry. 99/285 plant using the numeric than 10 generating keypad. sets. Back-up to perform GS 1 Rental application Stop Faults Alarms Stop Faults Alarms A633: Power plant without shared switching unit without Normal/Emergency Digital Bus Number of gen sets in power plant 2 Genset number 1 Validation 9. Press the generating set number on the touch screen. Back-up to perform GS 1 Rental application A633: Power plant without shared switching unit Base identification without Normal/Emergency Digital Bus 1 power plant Number of gen sets in 2 Genset number 1 2 Validation Valid Esc. 10. Select the number of the generating set with the arrows. The number of the generating set determines its type of connection, see the section “Electrical connections” Important 11. Press “Valid” to confirm the entry. 100/285 Back-up to perform GS 1 Rental application Stop Faults Alarms Stop Faults Alarms A633: Power plant without shared switching unit without Normal/Emergency Digital Bus Number of gen sets in power plant 2 Genset number 1 Validation 12. Press “Validation" on the touch screen. Back-up to perform GS 1 Rental application A633: Power plant without shared switching unit without Normal/Emergency Digital Bus Number of gen sets in power plant 2 Genset number 1 Validation Saving in flash … 13. The Kerys saves your new configuration. 101/285 14. After returning to the Kerys home screen, The configuration will only be taken into account if the following operations are carried out: Turn on the battery isolator switch. Wait 5 seconds. Turn off the battery isolator switch. Important Operations to be carried out on each generating set of the power plant. Important 6.3.8 Use 6.3.8.1. Choice of priority generating set in power plant (if equipped) Mnemonic aid info for menus: “1” – “7” – “4” – “3” – “GS selection” “Priority selection” “Valid” 15/07/09 19:10 :00 GS 1 Welcome Stop Faults -1Operation -6System -2Fault finding -5Configuration -3Archiving & Metering 1. Alarms -4Maintenance Press “Operation” on the touch screen. 102/285 15/07/09 19:10 :00 GS 1 Welcome Stop Faults Alarms -0Welcome -1Operation 2. -2Function keys -7User adjustments -3Synchro. column -6Alarms & Faults -4Central unit measure. summary -5Measurements Press “User settings” on the touch screen. 15/07/09 19:10 :00 GS 1 User adjustments -0Operation -1Set point -2Output threshold -3Wattmetric Control -4User parameters (1/2) 3. Press “User parameters (1/2)” on the touch screen. 103/285 Stop Faults Alarms 15/07/09 19:10 :00 Power return Confirmation request User parameters (1/2) GS 1 Stop No load test time delay (sec) : Without Faults Alarms 600 Power 1 Power loss time delay (sec) : 3 Power return time delay (sec) : 180 Inversion in non-coupl. In emergency mode Whithout Inversion in non-coupl. In normal mode Whithout -1Set point 4. -2Wattmetric COntrol -3Generating set priority Press “Generating set priority” on the touch screen. 15/07/09 19:10 :00 Generating set priority GS 1 Stop Faults Modification GS select. Priority select 01 Valid Return to the previous priorities Display GS 1 2 PRI 02 01 -1General parameters 5. -2Thresholds Press the selection arrows on the touch screen to select the generating set. 104/285 02 Alarms 15/07/09 19:10 :00 Generating set priority GS 1 Stop Faults Alarms Modification GS select. Priority select 01 02 Return to the previous priorities Valid Display GS 1 2 PRI 02 01 -1General parameters 6. -2Thresholds Press the selection arrows on the touch screen to select the priority of the generating set selected. 15/07/09 19:10 :00 Generating set priority GS 1 Stop Faults Modification GS select. Priority select 01 Return to the previous priorities Valid Display GS 1 2 PRI 02 01 -1General parameters 7. -2Thresholds Press “Valid” on the touch screen. 105/285 02 Alarms Back-up to perform Generating set priority GS 1 Stop Faults Alarms Modification GS select. Priority select 01 Valid 02 Return to the previous priorities Display GS 1 2 PRI 02 01 -1General parameters 8. -2Thresholds Press “Save" on the touch screen. Back-up to perform Generating set priority GS 1 Stop Faults Modification GS select. Priority select 01 Save in flash Valid Valid GS 1 2 PRI 02 01 -1General parameters 9. Return to the previous priorities Display -2Thresholds Press “Valid” on the touch screen. 106/285 Esc. 02 Alarms Back-up to perform Generating set priority GS 1 Stop Faults Alarms Modification GS select. Priority select 01 02 Return to the previous priorities Valid Saving in flash … Display GS 1 2 PRI 02 01 -1General parameters -2Thresholds 10. The Kerys saves your new configuration. 15/07/09 19:10 :00 Generating set priority GS 1 Stop Faults Alarms Modification GS select. Priority select 01 02 Return to the previous priorities Valid Display GS 1 2 PRI 02 01 -1General parameters 11. -2Thresholds Press “Generating set priority” on the touch screen to return to the home screen. The configuration will only be considered valid if the following operations are carried out: Open the battery cutout. Wait 5 seconds. Close the battery cutout. Important 107/285 6.3.8.2. Starting, tests and stop In manual mode Starting Check there are no faults: grey: no fault. red: fault present. grey: no alarm. orange: alarm present. If faults are present, the fault management screen can be accessed by pressing Reset. Refer to the section “Alarms and Faults” in the “Operating menus” to eliminate the faults. If no faults are present, manual mode can be activated by pressing Manu. 108/285 The manual start-up phase will begin once key 1 in the test keypad is pressed. The start-up request is maintained until the generating set starts (it is not necessary to keep key 1 pressed). This method may not, under any circumstances, be used to turn the engine over manually. During the start-up phase and until the alternator voltage and speed of the generating set stabilise, the green LED under the generating set symbol flashes and then lights up permanently once the phase is complete. Tests If no faults are present, automatic mode can be activated by pressing Auto. The test starting phase is then initiated after pressing 1 on the test keypad. 109/285 Pressing 1 on the test keypad brings up the following window for selecting the test type. 15/07/09 19 : 10 :00 GS 1 I1(A) Operation 2701 Manu F.P Faults Alarms 0,9 L Test selected Select the test to be carried out Under load test Speed (rpm) 1505 Operating time: 10 :05 + Speed -1Function keys No load test Esc - Speed +U Q (kVAr) 765 -U -3-2Power plant Synchronisation column measurements summary Using the KERYS Tactil Man-Machine Interface, the under load test is started by pressing the corresponding key. Using the KERYS Tactil Man-Machine Interface, the off load test is started by pressing the corresponding key. After validation of the test, the orange LED on the test keypad lights up steady. During the start-up phase, and until the alternator voltage and generating set speed stabilise, the green LED underneath the symbol for the generating set flashes and becomes steady at the end of this phase. The installation is then controlled via the programmable controller in accordance with the configuration of the application: normal/emergency source switchover grid coupling etc. Important The Normal/Emergency switchover with grid coupling is only possible by carrying out a load test. The purpose of the off load test is to start a single GS or to couple a power plant (x generating sets) to the emergency busbar. 110/285 At any time the generating set may be stopped by pressing Stop or by pressing 0 on the test keypad. Important Pressing Stop may interrupt the power supply, depending on its status when the key is pressed (e.g. isolated grid operation). The generating set will stop after a cooling delay (180 seconds by default). The green LED underneath the generating set symbol goes out to indicate that the generating set has stopped. Switching off The generating set may be stopped at any time by pressing Stop or 0 on the test keypad. The green LED underneath the generating set symbol goes out to indicate that the generating set has stopped. Pressing Stop stops the generating set immediately. Pressing 0 does not stop the generating set immediately (generating set stabilisation time delay). Important 111/285 In automatic mode Starting Check there are no faults: grey: no fault. red: fault present. grey: no alarm. orange: alarm present. If faults are present, the fault management screen can be accessed by pressing Reset. Refer to the section “Alarms and Faults” in the Operating menus” to eliminate the faults. If no faults are present, manual mode can be activated by pressing Auto. In AUTO mode, except for the test functions, the generating set starts as a result of an external command which may be triggered by various sources: power loss EJP command (France only) client command. 112/285 The installation is then controlled via the automatic systems in accordance with the configuration of the application: inversion of normal/emergency source grid coupling etc. Tests If no faults are present, automatic mode can be activated by pressing Auto. The test starting phase is then initiated after pressing 1 on the test keypad. Pressing 1 on the test keypad brings up the following window for selecting the test type. 15/07/09 19 : 10 :00 GS 1 I1(A) Operation 2701 Manu F.P Faults Alarms 0,9 L Test selected Select the test to be carried out Under load test Speed (rpm) 1505 Operating time: 10 :05 + Speed -1Function keys No load test Esc - Speed +U Q (kVAr) 765 -U -3-2Power plant Synchronisation column measurements summary Using the KERYS Tactil Man-Machine Interface, the under load test is started by pressing the corresponding key. Using the KERYS Tactil Man-Machine Interface, the off load test is started by pressing the corresponding key. 113/285 After validation of the test, the orange LED on the test keypad lights up steady. During the start-up phase, and until the alternator voltage and generating set speed stabilise, the green LED underneath the symbol for the generating set flashes and becomes steady at the end of this phase. The installation is then controlled via the programmable controller in accordance with the configuration of the application: normal/emergency source switchover grid coupling etc. Important The Normal/Emergency switchover with grid coupling is only possible by carrying out a load test. The purpose of the off load test is to start a single GS or to couple a power plant (x generating sets) to the emergency busbar. At any time the generating set may be stopped by pressing Stop or by pressing 0 on the test keypad. Important Pressing Stop may interrupt the power supply, depending on its status when the key is pressed (e.g. isolated grid operation). The generating set will stop after a cooling delay (180 seconds by default). The green LED underneath the generating set symbol goes out to indicate that the generating set has stopped. 114/285 Switching off The generating set may be stopped at any time by pressing 0 on the test keypad. Pressing Stop may cause an interruption in the power supply depending on its status when the button is pressed (e.g. isolated grid operation). The generating set will stop after the cooling delay (180 seconds by default). Important The green LED underneath the generating set symbol goes out to indicate that the generating set has stopped. 6.3.8.3. Rental options Damper valve (Optional) X If the generating set stops when the valve damper is closed, repair the fault. Y Display the fault according. Z Press “Reset” to clear the fault after it has been repaired. [ If faults persist, repair them. 115/285 Air preheating (Optional) Turn the switch to “ON” to initiate preheating of the generating set. AIR PREHEATING OFF ON In the case of a power plant, the position of the air preheating switches must NECESSARILY be the same on all the switches of the generating sets in the power plant. Important Bi-frequency (Optional) Turn the switch to the desired frequency and voltage. FREQUENCY 50Hz 400V 50Hz 440V 60Hz 480V Earthing system Turn the switch to the desired earthing system. EARTHING SYSTEM IT 1: 2: 3: TT TN IT TN (TNS) TT (TT or EDF APPLICATION) The EDF earthing system is only used in the so-called rental configurations. The switch must necessarily correspond to the wiring described in the section on “Connection of the generating sets”. Important 116/285 7. Maintenance schedule 7.1. Reminder of use The maintenance interval frequency and the operations to be carried out are outlined in the maintenance schedule, given as a guideline. N.B. the environment in which the generating set is operating determines this schedule. If the generating set is used in extreme conditions, shorter intervals between maintenance procedures should be observed These maintenance intervals only apply to generating sets running on fuel, oil and coolant which conform to the specifications given in this manual. 7.2. Engine R = Replace I = Inspection (includes, if necessary, cleaning, adjustment, lubrication and charge) First service inspection After the first 100 – 200 hours Fuel pre-filter, draining water / contamination Coolant level Drive belts Start and warm up engine Coolant / oil / fuel, leakage Inspection with VODIA (diagnostic tool) Engine and transmission, abnormal noises Stop engine Engine oil and oil filters / by-pass filter Restart engine Oil pressuer / oil leakage I I I I I I R I Every 50 – 600 hours Engine oil and oil filters / by-pass filter R After the first 1 000 hours Valve clearance I Every 500 hours Fuel tank (sludge trap), drain Inspection with VODIA (diagnostic tool) Fuel pre-filter, draining condensed water Air filter inserts (indicator), engine Radiator Drive belts Batteries, electrolyte level At least every (month) 12 24 48 At least every (month) 12 24 48 At least every (month) 12 24 48 At least every (month) 12 24 48 R I I I I I I Every 1 000 hours Fuel filter Air filter insert Fuel pre-filter Coolant filter (if fitted). Not at same time as coolant change. R R R R Every 2 000 hours Valve clearance I Every 2 000 hours Turbo Turbo, Wastegate Engine, with respect to leakage Engine hoses, cables and clamps Engine, cleaning and painting Air filter, tank breather Air filter compressor I I I I I R R 117/285 Every 4 000 hours Belt tensioner Drive belt Coolant (green) 48 At least every (month) 12 24 48 I R R Every 8 000 hours Coolant VCS (yellow) 7.3. At least every (month) 12 24 R Alternator After 20 hours in operation, check the tightness of all the mounting bolts, the general condition of the machine and the various electrical connections of the installation. The bearings fitted on the machine are greased for life to around the service life of the grease (depending on use) = 20 000 hours or 3 years. Regularly clean the inlet and outlet grid. 118/285 8. Battery Fit the battery so that it is properly ventilated. Maintenance should only be carried out by qualified personnel. If replacing the batteries, use the same type of batteries. Do not throw the old battery in the fire. Only use insulated tools (the operator should not be wearing a watch, chain or any metal object). Never use sulphuric acid or acid water to top up the electrolyte level. Use an approved battery fluid. Batteries release oxygen and hydrogen gas, which are flammable. Never bring flames or sparks near the battery (risk of explosion). Discharge any static electricity before handling the batteries by first touching an earthed metal surface. Do not use the battery when the fluid level is below the minimum required level Using a battery with a low electrolyte level could result in an explosion. Do not short the battery terminals with a tool or other metal object. When disconnecting battery cables, remove the cable from the negative (-) terminal first. When reconnecting the battery, connect the positive lead (+) first. Charge the battery in a well-ventilated place, with all the filler caps opened. Ensure that the battery terminals are correctly tightened. A loose cable clamp can cause sparks that could result in an explosion. Before servicing electrical components or performing electric welding, set the battery switch to the [OFF] position or disconnect the battery negative cable (-) to cut off the electrical current. Electrolyte contains dilute sulphuric acid. Careless handling of the battery causing contact with sulphuric acid could damage your eyesight or cause burns. Wear safety goggles and rubber gloves when working with the battery (topping-up fluid, charging, etc.) If electrolyte comes into contact with your skin or clothes, wash it off immediately with plenty of water, then carefully wash the area with soap. Danger If electrolyte comes into contact with your eyes, rinse immediately with plenty of water and seek medical attention as soon as possible. If electrolyte is accidentally swallowed, gargle with plenty of water and drink large quantities of water. Consult a doctor immediately. Large quantities of electrolyte should be rinsed off using a neutralising agent. A common method is to use a solution of 500g of bicarbonate of soda diluted in 4 litres of water. The bicarbonate of soda solution should be added until the reaction has finished (lather). The remaining liquid should be rinsed off with water and left to dry. Dry batteries do not require any servicing Batteries ready for use must be recharged at the latest when the acid density drops below 1.20. 8.1. Storage and transport Batteries ready for use must be stored in a cool and dry place (frost-free) protected from the sun (self-discharge). Batteries must be transported and stored vertically (risk of acid spillage) Leave the terminal cover on the positive terminal 119/285 8.2. Battery setting into service Batteries filled with acid have a density of 1.28 g/ml and are charged. In the case of dry batteries, fill each battery cell with acid up to the maximum level mark or to 15 mm above the plates. Let the battery rest for 20 minutes. Before fitting the battery, stop the engine and any power consumer, clean the terminals and give them a light coating of grease. When connecting, connect the positive terminal (+) first, and then the negative terminal (-). 8.3. Check Acid density 1.27 1.25 1.20 1.19 1.13 Charge status 100% 80% 60% 40% 20% Voltage when idle Above 12.60 V 12.54 V 12.36 V 12.18 V Under 11.88 V 120/285 From 50 % recharge Risk of sulphation Unusable 8.4. Load preconization Highly discharged or sulphated batteries (formation of whitish lead sulphate deposit on the plates, which becomes hard and insoluble to acid; this deposit reduce the active surface of the plates, and increases their internal resistance) can no longer regenerate or be charged in a generating set. A discharged battery should be recharged immediately, or else it will suffer irreparable damage. Important Battery charge When several batteries are connected together, the following points should be checked: Are the batteries connected in series? Has the correct voltage been chosen? 1 battery x 12 V , 3 x 36V batteries. Adjust the charge current to the lowest battery. The power difference between the batteries must be as low as possible. Example of charge: 12V 60 Ah battery = charging current 6 A. Charge status: 50% (acid density 1.21/voltage when idle 12.30V). The battery is short 30 Ah, and this must be recharged. Charge factor: 1.2. Ah x 1.2 = 36 Ah to be charged. Charging current: 6A approximately 6 hours charging required. Recharging is complete when the battery voltage and the acid density stop increasing. → The charging current must always be 1/10th of the nominal capacity of the battery. The power of the charger must be suitable for the battery to be charged and the charging time available. You need to use an automatic charger able to provide a sufficient voltage and charging current, as well as a compensation voltage to handle spontaneous battery discharge. 121/285 8.5. Faults and remedies Fault observed The acid heats up when a new battery is filled The acid escapes through the filler holes Acid level too low Acid level too low Incorrect operation from start-up Acid density too high Starting problems Starting test incorrect Battery terminals melted One or two cells release a lot of gas at high charge The battery discharges very quickly Short service life High water consumption The battery explodes - - - Probable origin Incorrect composition Incorrect storage Prolonged storage in a damp place Battery overflow during filling Battery tray not leaktight Significant gas formation caused by too high a charging voltage Insufficient charge Short circuit in the current circuit Consumption fault The battery has been filled with acid instead of water Battery empty Battery used up or faulty Capacity too low Battery sulphated Incorrect electrical connection Incorrect battery wiring Cell(s) faulty - Charge status too low - Short circuit in the current circuit - High self-discharge (for example: through electrolyte contamination) - Sulphation (storage of discharged battery) - Incorrect battery part no. - Too many repeated deep discharges - Battery stored too long without charge - Overload Charging voltage too high Spark after battery charging Short circuit Connection or disconnection during charging - Internal fault (for example: interruption) and low electrolyte level 122/285 Measures or observations Cool Charge Check the acid density Reduce the battery fluid level Replace the battery Check the charger and repair if necessary. - Recharge - Check the electrical installation - - Reduce the acid level and fill with distilled water. Repeat the operation if need be. - Recharge the battery - Fit a new battery - Tighten the ends of the battery cables, or replace them if necessary - Fit a new battery - Check the charge - Replace the battery - Define the correct battery part no. for the recommended use - Think about charging the battery using a regulator - Check the charger (voltage regulator) - Replace the battery (beware of fire and sparks) - Ensure there is sufficient ventilation 9. Appendix 9.1. Appendix A – Engine user and maintenance manual 123/285 124/285 User guide and maintenance manual VOLVO Engine TAD940VE TAD941VE TAD942VE TAD943VE TAD940GE TAD941GE 47702660 01/01/2012 33522062701_2_1 125/285 126/285 127/285 128/285 129/285 130/285 131/285 132/285 133/285 134/285 135/285 136/285 137/285 138/285 139/285 140/285 141/285 142/285 143/285 144/285 145/285 146/285 147/285 148/285 149/285 150/285 151/285 152/285 153/285 154/285 155/285 156/285 157/285 158/285 159/285 160/285 161/285 162/285 163/285 164/285 165/285 166/285 167/285 168/285 169/285 170/285 171/285 172/285 173/285 174/285 175/285 176/285 177/285 178/285 179/285 180/285 181/285 182/285 183/285 184/285 185/285 186/285 187/285 188/285 189/285 190/285 191/285 192/285 193/285 194/285 195/285 196/285 197/285 198/285 199/285 200/285 201/285 202/285 203/285 204/285 205/285 206/285 207/285 208/285 9.2. Appendix B - Alternator user and maintenance manual 209/285 210/285 User guide and maintenance manual LEROY SOMER Alternator LSA46.2 L6 - L9 LSA46.2 M3 - M5 46-2 SHUNT & AREP & PMG 3856 h 01/03/2012 33522061001_8_1 211/285 212/285 3856 en - 2011.01 / h 371 364 367 49 48 124 120 122 177 198 41 466 15 n ive be g o t s i ual d user man n This to the e 322 325 320 30 321 1 31 37 347 323 33 34 4 343 100 78 28 LSA 46.2 - 4 POLES ALTERNATORS Installation and maintenance 213/285 70 349 79 91 90 36 LEROY-SOMER Installation and maintenance 3856 en - 2011.01/ h LSA 46.2 - 4 POLES ALTERNATORS This manual concerns the alternator which you have just purchased. We wish to draw your attention to the contents of this maintenance manual. SAFETY MEASURES WARNING SYMBOLS Before using your machine for the first time, it is important to read the whole of this installation and maintenance manual. We wish to draw your attention to the following 2 safety measures which must be complied with: All necessary operations and interventions on this machine must be performed by a qualified technician. a) During operation, do not allow anyone to stand in front of the air outlet guards, in case anything is ejected from them. Our technical support service will be pleased to provide any additional information you may require. b) Do not allow children younger than 14 to go near the air outlet guards. The various operations described in this manual are accompanied by recommendations or symbols to alert the user to the potential risk of accidents. It is vital that you understand and take notice of the different warning symbols used. A set of self-adhesive stickers depicting the various warning symbols is included with this maintenance manual. They should be positioned as shown in the drawing below once the machine has been fully installed. Warning symbol for an operation capable of damaging or destroying the machine or surrounding equipment. WARNING The alternators must not be put into service until the machines in which they are to be incorporated have been declared compliant with Directives EC and plus any other directives that may be applicable. Warning symbol for general danger to personnel. Note: LEROY-SOMER reserves the right to modify the characteristics of its products at any time in order to incorporate the latest technological developments. The information contained in this document may therefore be changed without notice. WARNING Warning symbol for electrical danger to personnel. Copyright 2005 : MOTEURS LEROYSOMER This document is the property of: MOTEURS LEROY SOMER. It may not be reproduced in any form without prior authorization. All brands and models have been registered and patents applied for. 2 214/285 LEROY-SOMER Installation and maintenance 3856 en - 2011.01/ h LSA 46.2 - 4 POLES ALTERNATORS CONTENTS 1 - RECEIPT.............................................................................................................................4 1.1 - Standards and safety measures....................................................................................4 1.2 - Inspection......................................................................................................................4 1.3 - Identification.................................................................................................................. 4 1.4 - Storage.........................................................................................................................4 1.5 - Applications................................................................................................................... 4 1.6 - Contraindications to use................................................................................................4 2 - TECHNICAL CHARACTERISTICS.....................................................................................5 2.1 - Electrical characteristics................................................................................................5 2.2 - Mechanical characteristics............................................................................................5 3 - INSTALLATION................................................................................................................... 6 3.1 - Assembly.......................................................................................................................6 3.2 - Checks prior to first use.................................................................................................7 3.3 - Terminal connection diagrams.......................................................................................7 3.4 - Commissioning........................................................................................................... 10 3.5 - Setting up.................................................................................................................... 10 4 - SERVICING - MAINTENANCE.......................................................................................... 11 4.1 - Safety measures......................................................................................................... 11 4.2 - Routine maintenance.................................................................................................. 11 4.3 - Fault detection............................................................................................................. 11 4.4 - Mechanical defects.....................................................................................................12 4.5 - Electrical faults............................................................................................................ 12 4.6 - Dismantling, reassembly.............................................................................................14 4.7 - Installation and maintenance of the PMG....................................................................16 4.8 - Table of characteristics................................................................................................17 5 - SPARE PARTS.................................................................................................................. 18 5.1 - First maintenance parts...............................................................................................18 5.2 - Technical support service............................................................................................18 5.3 - Accessories................................................................................................................. 18 5.4 - Exploded views, parts list and tightening torque..........................................................19 EC declaration of incorporation..........................................................................................22 3 215/285 Installation and maintenance LEROY-SOMER 3856 en - 2011.01/ h LSA 46.2 - 4 POLES ALTERNATORS 1 - RECEIPT 1.1 - Standards and safety measures • C : excitation system (C : AREP / J : SHUNT or PMG / E : COMPOUND) • 6/4 : winding number / number of poles. 1.2 - Inspection 1.3.1 - Nameplate So that you can identify your machine quickly and accurately, we suggest you write its specifications on the nameplate below. On receipt of your alternator, check that it has not suffered any damage in transit. If there are obvious signs of knocks, contact the transporter (you may be able to claim on their insurance) and after a visual check, turn the machine by hand to detect any malfunction. 1.3 - Identification The alternator is identified by means of a nameplate fixed on the machine (see drawing). Make sure that the nameplate on the machine conforms to your order. The machine name is defined according to various criteria, for example : LSA 46.2 M5 C6/4 • LSA : name used in the PARTNER range M : Marine C : Cogeneration T : Telecommunications • 46.2 : machine type • M5 : model 1.4 - Storage Prior to commissioning, machines should be stored : - Away from humidity (< 90%); after a long period of storage, check the machine insulation (section 3.2.1). To prevent the bearings from becoming marked, do not store in an environment with significant vibration. 1.5 - Application These alternators are mainly designed to produce electricity in the context of applications involving the use of generators. 1.6 - Contraindications to use Use of the machine is restricted to operating conditions (environment, speed, voltage, power, etc) compatible with the characteristics indicated on the nameplate. ALTERNATEURS LSA Date N 5700 125897 A15 Hz Min-1/R.P.M. 1500 Protection Cos Ø /P.F. 0,8 Cl. ther. / Th.class Régulateur/A.V.R. R 438 B Altit. m Masse / Weight Rlt AV/D.E bearing 6302 2 RS C3 Rlt AR/N.D.E bearing 6303 2 RS C3 Graisse / Grease 45g / 3600 h Valeurs excit / Excit. values en charge / full load à vide / at no load 166631 C US ALTERNATORS PUISSANCE / RATING Tension Voltage V Ph. Connex. kVA Continue Continuous kW 40C A kVA Secours Std by kW 27C A (*) Tension maxi. / maximum voltage Conforme à C.E.I 60034-1. According to I.E.C 60034-1. 4 216/285 Made in France - 1 024 959/a Our alternators comply with most international standards. See the EC Declaration of Incorporation on the last page. LEROY-SOMER Installation and maintenance 3856 en - 2011.01/ h LSA 46.2 - 4 POLES ALTERNATORS 2 - TECHNICAL CHARACTERISTICS 1.1 - Electrical characteristics The LSA 46.2 alternator is a machine without sliprings or revolving armature brushes, wound as “2/3 pitch”, 6 or 12wire, with class H insulation and a field excitation system available in either SHUNT, AREP or «PMG» version (see diagrams and AVR manuals). 2.1.1 - Electrical options - Stator temperature detection sensors - Bearing sensors (PTC, PT100, etc) - Space heater Interference suppression conforms to standard EN 55011, group 1, class B (Europe). SHUNT SYSTEM 2.2 - Mechanical characteristics - Steel frame - Cast iron end shields - Protected ball bearings, greased for life - Mounting arrangements: IM 1201 (MD 35) foot and flange mounted, single-bearing with SAE coupling disc. IM 1001 (B 34) double-bearing with SAE flange and standard cylindrical shaft extension. - Drip-proof machine, self-cooled - Degree of protection: IP 23 2.1.1 - Mechanical options - Air inlet filter - Regreasable ball bearings - IP 44 protection STATOR : 12-wire (marking T1 to T 12) MAIN FIELD T1 T7 T2 T8 T3 T9 T4 T10 T5 T11 T6 T12 Varistor EXCITER 5+ Armature 6- Field R 250 AREP SYSTEM Power supply / Detection STATOR : 6 or 12-wire (marking T1 to T 12) MAIN FIELD Aux. windings T1 T7 T2 T8 T3 T9 T4 T10 T5 T11 T6 T12 Varistor EXCITER 5+ Armature 6- Field R 450 PMG SYSTEM STATOR : 6 or 12-wire (marking T1 to T12) MAIN FIELD Varistor EXCITER 5+ Armature Voltage reference T1 T7 T2 T8 T3 T9 T4 T10 T5 T11 T6 T12 PMG 6- Field R 450 Voltage reference 5 217/285 LEROY-SOMER Installation and maintenance 3856 en - 2011.01/ h LSA 46.2 - 4 POLES ALTERNATORS 3 - INSTALLATION Personnel undertaking the various operations indicated in this section must wear personal protective equipment appropriate for mechanical and electrical hazards. 3.1 - Assembly 3.1.2 - Coupling 3.1.2.1 - Single-bearing alternator Before coupling the machines, check that they are compatible by: - undertaking a torsional analysis of the transmission, - checking the dimensions of the flywheel and its housing, the flange, coupling discs and offset. WARNING All mechanical handling operations must be undertaken using suitable equipment and the machine must be horizontal. Check how much the machine weighs (see 4.8.3.) before choosing the lifting tool. 3.1.1 - Handling The generously-sized lifting rings are for handling the alternator alone. They must not be used to lift the genset. The choice of lifting hooks or handles should be determined by the shape of these rings. Choose a lifting system which respects the integrity and the environment of the alternators. When coupling the alternator to the prime mover, do not use the fan to turn the alternator or rotor. The holes of the coupling discs should be aligned with the flywheel holes by cranking the engine. Make sure the alternator is securely bedded in position during coupling. Check that there is lateral play on the crankshaft. 3.1.2.2 - Double-bearing alternator - Semi-flexible coupling Careful alignment of the machines is recommended, checking that the lack of concentricity and parallelism of both parts of the coupling do not exceed 0.1 mm. This alternator has been balanced with a 1/2 key. 3.1.3 - Location The room where the alternator is placed must be ventilated to ensure that the ambient temperature cannot exceed the data on the nameplate. 3.2 - Checks prior to first use 3.2.1 - Electrical checks During this operation, do not allow anyone to stand under the load. Under no circumstances should an alternator, new or otherwise, be operated if the insulation is less than 1 megohm for the stator and 100,000 ohms for the other windings. 6 218/285 Installation and maintenance LEROY-SOMER 3856 en - 2011.01/ h LSA 46.2 - 4 POLES ALTERNATORS There are 2 possible methods for restoring the above minimum values. a) Dry out the machine for 24 hours in a drying oven at a temperature of 110 °C (without the regulator). b) Blow hot air into the air intake, having made sure that the machine is rotating with the exciter field disconnected. Note : Prolonged standstill: In order to avoid these problems, we recommend the use of space heaters, as well as turning over the machine from time to time. Space heaters are only really effective if they are working continuously while the machine is stopped. - the standard direction of rotation is clockwise as seen from the shaft end (phase rotation in order 1 - 2 - 3). For anti-clockwise rotation, swap 2 and 3. - the winding connection corresponds to the site operating voltage (see section 3.3). 3.3 - Terminal connection diagrams To modify the connection, change the position of the stator cables on the terminals. The winding code is specified on the nameplate. 3.3.1 - Terminal connection: 12 wire The connection accessories are detailed in section 5.3.3. WARNING Ensure that the alternator has the degree of protection matching the defined environmental conditions. 3.2.2 - Mechanical checks Before starting the machine for the first time, check that: - all fixing bolts and screws are tight. - the cooling air is drawn in freely. - the protective grilles and housing are correctly in place. Connection codes A T1 3-phase Voltage L.L L1(U) Winding T7 T4 T12 N T10 T5 T9 T3 T8 T1 D 190 - 240 7 220 - 8 - 190 - 208 3-phase T7 T12 T9 T6 T3 L3(W) N T10 T11 50 Hz 60 Hz 6 380 - 415 380 - 480 7 440 - 8 - 380 - 416 Winding T4 R 250 voltage detection : 0 => (T8) / 110 V => (T11) R 450 voltage detection : 0 => (T3) / 380 V => (T2) T5 T8 T2 L2(V) T12 T11 T10 R 250 voltage detection : 0 => (T8) / 110 V => (T11) R 450 voltage detection : 0 => (T3) / 220 V => (T2) L2(V) L1(U) Factory connection 60 Hz 190 - 208 T6 L3(W) 50 Hz 6 T2 T11 Any intervention on the alternator terminals during reconnection or checks should be performed with the machine stopped. 9 500 T9 T6 T5 T4 T8 T7 T3 T11 T10 T6 T5 T4 L2(V) T1 L1(U) N NDE T12 L3(W) T2 T9 T8 T7 NDE T3 L3(W) T2 L2(V) T1 L1(U) N 600 Winding 9 : R 450 voltage detection + transformer (See specific diagram AREP or SHUNT) In case of reconnection, ensure that AVR voltage detection is correct ! The factory can supply a set of flexible shunts and special connection links as an option for making these connections. (*). 7 219/285 Installation and maintenance LEROY-SOMER 3856 en - 2011.01/ h LSA 46.2 - 4 POLES ALTERNATORS Connection codes Voltage L.L 50 Hz 60 Hz 6 220 - 240 220 - 240 7 240 - 254 - 8 - 220 - 240 Winding FF 1 phase T2 T3 T11 T5 T4 T1 L T12 T8 T6 T9 T7 T10 Voltage LM = 1/2 voltage LL T12 1 phase or 3-phase T1 T9 T4 T7 T6 T3 L3(W) L T10 T8 T11 T5 M 50 Hz 60 Hz 6 220 - 240 220 - 240 7 240 - 254 - 8 - 220 - 240 Winding L1(U) F T2 R 250 voltage detection : 0 => (T8) / 110 V => (T11) R 450 voltage detection : 0 => (T3) / 220 V => (T2) L2(V) L Voltage LM = 1/2 voltage LL G 1 PH T6 T12 T7 M T1 T4 T3 T9 T10 L T2 T5 T11 Voltage LM = 1/2 voltage LL L T8 Winding 50 Hz 6 220 - 240 T3 T9 T6 T11 T2 T5 T8 T10 T4 T1 T7 7 250 - 260 - 8 200 220 - 240 R 250 voltage detection : 0 => (T8) / 110 V => (T11) R 450 voltage detection : 0 => (T3) / 220 V => (T2) In case of reconnection, ensure that AVR voltage detection is correct ! L1(U) M NDE T12 T6 T3 T9 11 T8 T2 T5 T10 T1 T4 L2(V) * ( ) L3(W) T7 L2(V) L1(U) M NDE Operating phases L2 (V), L3 (W) single phase 60 Hz 220 - 240 * ( ) T12 R 250 voltage detection : 0 => (T4) / 110 V => (T1) R 450 voltage detection : 0 => (T10) / 220 V => (T1) L M Factory connection * ( ) T12 T3 T6 T9 T2 T11 T5 T8 L3(W) L2(V) T10 T4 T7 NDE T1 M The factory can supply a set of flexible shunts and special connection links as an option for making these connections. (*). 8 220/285 Installation and maintenance LEROY-SOMER 3856 en - 2011.01/ h LSA 46.2 - 4 POLES ALTERNATORS 3.3.2 - Terminal connection: 6 wire (not possible with the R 250) Connection codes Voltage L.L L1(U) D T1 3-phase N T4 Factory connection Winding 50 Hz 60 Hz 6S 7S 8S 380 - 415 380 - 480 440 - - 380 - 416 T6 T3 - Winding 50 Hz 60 Hz 6S 220 - 240 220 - 277 7S 240 - 254 9S L1(U) 1 phase or 3-phase T1 T3 8S T4 T2 T5 T2 T6 T1 L2(V) L1(U) N 600 L2(V) L3(W) L3(W) T4 L3(W) NDE Winding 9 : R 450 voltage detection + transformer (See specific diagram) T2 T6 T3 R 450 voltage detection : 0 => (T3) / 380 V => (T2) T5 F T5 - - T3 T4 220 - 240 T6 L3(W) T2 L2(V) T1 L1(U) R 450 voltage detection : 0 => (T3) / 220 V => (T2) L2(V) * ( ) T5 NDE Operating phases : L2 (V), L3 (W) single phase In case of reconnection, ensure that the AVR voltage detection is correct ! The factory can supply a set of flexible shunts and special connection links as an option for making these connections. (*). 3.3.3 - Option connection diagram R 791 T interference suppression kit (standard for CE marking) Connections Black Black Black Blue White A D F T1 T2 T3 N T1 T2 T3 N T1 T2 T3 Remote voltage potentiometer ST4 Voltage adjustment via remote potentiometer Current transformer connection (optional) Coupling D - PH 1 In - Secondary 1 A Neutral link Coupling D & A- PH 1 In - Secondary 1A (coupl. D) T4 P2 P1 6-wire Neutral link Anti condensation heater 101 T10 P2 P1 12-wire Thermistor (PTC) temperature 103 250W - 220 V 102 104 Ph1 130 C blue wire Ph2 150C black wire Ph3 180 C red/white wire 9 221/285 LEROY-SOMER Installation and maintenance 3856 en - 2011.01/ h LSA 46.2 - 4 POLES ALTERNATORS 3.3.4 - Connection checks 3.4 - Commissioning Electrical installations must comply with the current legislation in force in the country of use. Check that: - The residual circuit-breaker conforms to legislation on protection of personnel, in force in the country of use, and has been correctly installed on the alternator power output as close as possible to the alternator. (In this case, disconnect the wire of the interference suppression module linking the neutral). - Any protection devices in place have not been tripped. - If there is an external AVR, the connections between the alternator and the cabinet are made in accordance with the connection diagram. - There is no short-circuit phase-phase or phase-neutral between the alternator output terminals and the generator set control cabinet (part of the circuit not protected by circuitbreakers or relays in the cabinet). - The machine should be connected with the busbar separating the terminals as shown in the terminal connection diagram. The machine can only be started up and used if the installation is in accordance with the regulations and instructions defined in this manual. The machine is tested and set up at the factory. When first used with no load, make sure that the drive speed is correct and stable (see the nameplate). With the regreasable bearing option, we recommend greasing the bearings at the time of commissioning (see 4.2.3). On application of the load, the machine should achieve its rated speed and voltage; however, in the event of abnormal operation, the machine setting can be altered (follow the adjustment procedure in section 3.5). If the machine still operates incorrectly, the cause of the malfunction must be located (see section 4.4). 3.5 - Setting up The various adjustments during tests must be made by a qualified engineer. Ensure that the drive speed specified on the nameplate is reached before commencing adjustment. After operational testing, replace all access panels or covers. The AVR is used to make any adjustments to the machine. 10 222/285 Installation and maintenance LEROY-SOMER 3856 en - 2011.01/ h LSA 46.2 - 4 POLES ALTERNATORS 4 - SERVICING - MAINTENANCE 4.1 - Safety measures Servicing or troubleshooting must be carried out strictly in accordance with instructions so as to avoid the risk of accidents and to maintain the machine in its original state. All such operations performed on the alternator should be undertaken by personnel trained in the commissioning, servicing and maintenance of electrical and mechanical components, who must wear personal protective equipment appropriate for mechanical and electrical hazards. Before any intervention on the machine, ensure that it cannot be started by a manual or automatic system and that you have understood the operating principles of the system. 4.2 - Routine maintenance 4.2.1 - Checks after start-up After approximately 20 hours of operation, check that all fixing screws on the machine are still tight, plus the general state of the machine and the various electrical connections in the installation. 4.2.2 - Bearings As standard, the alternator is fitted with permanently greased bearings. As an option, they may be regreasable. It is advisable to lubricate the alternator during operation. Time intervals and quantity of grease are given in the table below. NDE/DE bearing Quantity of grease Regreasing interval 6316 C3 6315 C3 33 g 30 g 4000 H 4500 H Lubrication intervals are given for grease type: LITHIUM - standard - NLGI 3. In the factory, the grease used for lubrication is: ESSO - Unirex N3. Before using another grease, check for compatibility with the original one. Monitor the temperature rise in the bearings (see section 4.4). 4.2.3 - Electrical servicing Commercially-available volatile degreasing agents can be used. WARNING Do not use: trichlorethylene, perchlorethylene, trichloroethane or any alkaline products. These operations must be performed at a cleaning station, equipped with a vacuum system that collects and flushes out the products used. The insulating components and the impregnation system are not at risk of damage from solvents. Avoid letting the cleaning product run into the slots. Apply the product with a brush, sponging frequently to avoid accumulation in the housing. Dry the winding with a dry cloth. Let any traces evaporate before reassembling the machine. 4.2.4 - Mechanical servicing WARNING Cleaning the machine using water or a highpressure washer is strictly prohibited. Any problems arising from such treatment are not covered by our warranty. Degreasing: Use a brush and detergent (suitable for paintwork). Dusting: Use an air gun. If the machine is fitted with air inlet and outlet filters, the maintenance personnel should clean them routinely at regular intervals. In the case of dry dust, the filter can be cleaned using compressed air and/or replaced if it is clogged. After cleaning the alternator, it is essential to check the winding insulation (see sections 3.2 and 4.8). 4.3 - Fault detection If, when commissioned, the alternator does not work normally, the source of the malfunction must be identified (see sections 4.4 and 4.5). 11 223/285 Installation and maintenance LEROY-SOMER 3856 en - 2011.01/ h LSA 46.2 - 4 POLES ALTERNATORS 4.4 - Mechanical defects Fault Action - If the bearing has turned blue or if the grease has turned black, change the bearing Excessive temperature rise in one or both bearings (bearing temperature more - Bearing not fully locked (abnormal play in the bearing cage) Bearing - Check the end shield alignment (flange not properly fitted) than 80 °C) with or without abnormal bearing noise - Air flow (intake-outlet) partially clogged or hot air is being recycled from the alternator Excessive temperature rise in the or engine Abnormal alternator housing (more than 40° C - Alternator operating at too high a voltage (> 105% of Un on load) temperature above the ambient temperature) - Alternator overloaded - Misalignment (coupling) Excessive vibration - Defective mounting or play in coupling - Rotor balancing fault (Engine - Alternator) Vibration Excessive vibration and humming noise - Phase imbalance coming from the machine - Stator short-circuit - System short-circuit - Mis-paralleling Possible consequences: Alternator damaged by a significant - Broken or damaged coupling Abnormal impact, followed by humming and - Broken or bent shaft extension noise vibration - Shifting and short-circuit of revolving field winding - Fan fractured or coming loose on shaft - Irreparable damage to rotating diodes, AVR, surge suppressor 4.5 - Electrical faults Fault Action Connect a new battery No voltage of 4 to 12 volts to at no load on terminals E- and E+, respecting the polarity, start-up for 2 to 3 seconds Voltage too low Check the drive speed Effect The alternator builds up and its voltage is still correct when the battery is removed The alternator builds up but its voltage does not reach the rated value when the battery is removed The alternator builds up but its voltage disappears when the battery is removed Correct speed Speed too low Voltage too high Adjust AVR voltage potentiometer Voltage oscillations Adjust the AVR stability potentiometer Voltage correct at no load and too low when on load Run at no load and check the voltage between E+ and E- on the AVR Voltage disappears during operation Check the AVR, the surge suppressor, The voltage does not return to the the rotating diodes, and rated value replace any defective components Adjustment ineffective Check/Cause - Lack of residual magnetism - Check the connection of the voltage reference to the AVR - Faulty diodes - Armature short-circuit - Faulty AVR - Field windings open circuit (check winding) - Revolving field coil open circuit (check the resistance) Check the AVR connections (AVR may be faulty) - Field windings short-circuited - Rotating diodes burnt out - Revolving field coil short-circuited - Check the resistance Increase the drive speed (do not touch the AVR voltage pot. (P2) before running at the correct speed) Faulty AVR - Check the speed: possibility of cyclic irregularity If no effect: try normal or fast stability - Loose connections - Faulty AVR modes (ST2) - Speed too low when on load (or AVR LAM set too high) Voltage between E+ and E- (DC) - Check the speed (or AVR LAM set too high) SHUNT / AREP / PMG < 10V - Faulty rotating diodes Voltage between E+ and E- Short-circuit in the revolving field coil. Check the resistance. SHUNT / AREP / PMG > 15V - Faulty exciter armature. Check the resistance. - Exciter winding open circuit - Faulty exciter armature - Faulty AVR - Revolving field coil open circuit or short-circuited 12 224/285 Installation and maintenance LEROY-SOMER 3856 en - 2011.01/ h LSA 46.2 - 4 POLES ALTERNATORS 4.5.1 - Checking the winding You can check the winding insulation by performing a high voltage test. In this case, you must disconnect all AVR wires. Assembly A: Connect a 12 V battery in series with a rheostat of approximately 50 ohms - 300 W and a diode on both exciter field wires (5+) and (6-). ASSEMBLY A WARNING Diode 1A Damage caused to the AVR in such conditions is not covered by our warranty. C C C A A A ~ + C ~ ~ ~ C ~ - C ~ Cathode + - A C + - A C + Anode A - C A A A 4.5.3 - Checking the windings and rotating diodes using separate excitation 12V battery Assembly B: Connect a “Variac” variable power supply and a diode bridge on both exciter field wires (5+) and (6-). Both these systems should have characteristics which are compatible with the field excitation power of the machine (see the nameplate). 3) Run the unit at its rated speed. 4) Gradually increase the exciter field current by adjusting the rheostat or the variac and measure the output voltages on L1 - L2 - L3, checking the excitation voltage and current at no load (see the machine nameplate or ask for the factory test report). When the output voltage is at its rated value and balanced within 1% for the rated excitation level, the machine is in good working order. The fault therefore comes from the AVR or its associated wiring (ie. sensing, auxiliary windings). ASSEMBLY B 20 Diode 1A 10 90 100 0 Variac 5+ + 60 30 50 80 1) Stop the unit, disconnect and isolate the AVR wires. 2) There are two ways of creating an assembly with separate excitation. 40 6 - Exciter field 70 During this procedure, make sure that the alternator is disconnected from any external load and inspect the terminal box to check that the connections are fully tightened. Rh. 50Ω -300W + - 4.5.2 - Checking the diode bridge A diode in good working order should allow the current to flow only in the anode-tocathode direction. 6 - Exciter field 5 + AC 220V - DC 12V 13 225/285 LEROY-SOMER Installation and maintenance 3856 en - 2011.01/ h LSA 46.2 - 4 POLES ALTERNATORS 4.6 - Dismantling, reassembly (see sections 5.4.1. & 5.4.2.) WARNING During the warranty period, this operation should only be carried out in an LEROY-SOMER approved workshop or in our factory, otherwise the warranty may be invalidated. Whilst being handled, the machine should remain horizontal (rotor not locked in position). Check how much the machine weighs (see 4.8.3) before choosing the lifting method. 4.6.1 - Tools required To fully dismantle the machine, we recommend using the tools listed below: - 1 ratchet spanner + extension - 1 torque wrench - 1 set of flat spanners: 8 mm, 10 mm, 18 mm - 1 socket set: 8, 10, 13, 16, 18, 21, 24, 30 mm - 1 socket with male ferrule: 5 mm - 1 puller 4.6.2 -Screw tightening torque See section 5.4. 4.6.3 - Access to diodes - Open the air intake grille (51). - Disconnect the diodes. - Check the 6 diodes, change the diode bridges if necessary. 4.6.4 - Access to connections and the regulation system Access directly by removing the top of the cover (48) or the AVR access door (466). 4.6.5 - Replacing the NDE bearing - Remove the box lid (48) and the NDE panel (365) and remove the 2 screws from the part (122). - Disconnect the stator outputs (T1 to T12). - Disconnect the auxiliary winding wires AREP (X1,X2,Z1,Z2). - Disconnect the exciter wires (5+,6-). - Remove the air inlet louvre (51). If using a single-bearing or double-bearing machine with the regreasable bearing option: - Remove the bearing (78) thrust screws (72). - Remove all 4 screws (37). - Remove the shield (36). - Take out the antifriction bearing (70) using a puller with a central screw (see drawing below). - Fit the new antifriction bearing onto the shaft after heating it by induction to approximately 80 °C. - Mount the new preloading (wavy) washer (79) + the new “O” ring seal (349) in the shield (36) and coat the bearing seat with adhesive paste (see After Sales Service). If using a single-bearing or double-bearing machine with the regreasable bearing option: - Screw a threaded rod into the thrust bearing (78). - Refit the end shield on the machine using a dowel and nut in the shaft extension (see drawing). 14 226/285 LEROY-SOMER Installation and maintenance 3856 en - 2011.01/ h LSA 46.2 - 4 POLES ALTERNATORS - Slide the threaded rod into the shield hole to make it easier to assemble (see basic diagram). 4 78 36 Threaded rod Dowel Nut - Slide the threaded rod into the shield hole to make it easier to assemble (see basic diagram). - Tighten the bottom thrust bearing screws (78), remove the threaded rod and fit the other screws. - Tighten the 6 shield screws (31). - Refit the air outlet grille (33). 4.6.7 - Dismantling the rotor assembly - Remove the NDE shield (36) as described in section 4.6.5. - Remove the DE shield (30) as described in section 4.6.6 if it is a double-bearing machine. - Support the DE rotor (4) with a strap or with a support constructed in accordance with the following drawing. - Move the strap as the rotor moves in order to distribute the weight over it. Rotor NDE shield - Fit the thrust bearing screws (78), remove the threaded rod, fit the other screw and tighten up the assembly. - Tighten the 4 bearing screws (37). - Reconnect wires. - Fit the 2 support screws (122). - Fit the air inlet louvre (51). - Replace the cover. WARNING WARNING When dismantling the shields, you will need to change the antifriction bearings, the “O” ring seal, the preloading (wavy) washer and adhesive paste. 4.6.6 - Replacing the DE bearing - Remove the air outlet grille (33). - Remove the 6 screws (31) from the DE shield and the 3 screws (62) from the inner bearing retainer. - Remove the shield (30). - Take out the ball bearing (60) using a puller with a central screw (see section 4.6.5). - Fit the new bearing, after heating it by induction to approximately 80 °C. - Screw a threaded rod into the thrust bearing (68). - Refit the shield (30) on the machine. When dismantling the rotor involves changing parts or rewinding, the rotor must be rebalanced. 4.6.8 - Reassembling the machine - Mount the rotor (4) in the stator (1) (see drawing above) taking care not to knock the windings. 15 227/285 LEROY-SOMER Installation and maintenance 3856 en - 2011.01/ h LSA 46.2 - 4 POLES ALTERNATORS If using a single-bearing or double-bearing machine with the regreasable bearing option: - Mount the new preloading (wavy) washer (79) + the new “O” ring seal (349) in the shield (36). - Screw a threaded rod into the thrust bearing (78). - Refit the shield (36) on the machine using a dowel and nut in the shaft extension (see diagram). - Slide the threaded rod into the shield hole to make it easier to assemble (see diagram). - Fit the thrust bearing screws (78), remove the threaded rod, fit the other screw and tighten up the assembly. - Tighten the 4 bearing screws (37). - Reconnect exciter wires E+, E-. - Finish reassembling the cover. - Refit the flange (30) on the stator (1). - Tighten the screws (31). If using a double-bearing machine: - Mount the new preloading (wavy) washer (79) + the new “O” ring seal (349) in the shield (36). - Refit the shield (36) on the machine using a dowel and nut in the shaft extension (see diagram). - Tighten the 4 shield screws (37). - Reconnect exciter wires E+, E-. - Finish reassembling the cover. - Screw a threaded rod into the thrust bearing (68). - Refit the shield (30) on the machine. - Slide the threaded rod into the shield hole to make it easier to assemble (see basic diagram). - Fit the thrust bearing screws (68), remove the threaded rod, fit the other screw and tighten up the assembly. - Tighten the 6 shield screws (31). - Refit the air outlet grille (33). - Check that the machine assembly is correctly mounted and that all screws are tightened. To replace, follow the instructions in reverse order. 51 418 417 4.7 - Installation and maintenance of the PMG For the LSA 46.2, the PMG reference is: PMG 2. See the PMG manual ref : 4211. 4.6.9 - Dismantling and reassembly of the filters - Remove the grille (417) then take out the filter (418). Change the filter if necessary; please refer to section 4.2.5 for cleaning the filter. 16 228/285 Installation and maintenance LEROY-SOMER 3856 en - 2011.01/ h LSA 46.2 - 4 POLES ALTERNATORS 4.8 - Table of characteristics Table of average values Alternator - 4 poles - 50 Hz - Standard winding No. 6. (400V for the excitation values) The voltage and current values are given for no-load operation and operation at rated load with separate field excitation. All values are given to within ± 10% and may be changed without prior notification (for exact values, consult the test report). 4.8.1 - LSA46.2 average values Resistances at 20 °C (Ω) 0.022 0.0182 0.0148 0.012 0.0085 0.23 0.24 0.264 0.295 0.343 8.8 8.8 8.8 8.8 10 LSA 46.2 Auxil wdg: X1, X2 Auxil wdg: Z1, Z2 50 Hz 70 V 10 V 60 Hz 85 V 12 V 4.8.3 - Table of weights (values given for information only) LSA 46.2 Total weight (kg) LSA 46.2 Stator L/N Rotor Field Armature M3 M5 L6 L9 VL12 4.8.2 - Voltage of auxiliary windings at no load 0.035 0.035 0.035 0.035 0.037 Rotor (kg) M3 600 250 M5 700 260 L6 800 290 L9 850 320 VL12 1000 380 Resistance of AREP auxiliary windings at 20 °C (Ω) LSA 46.2 Auxil wdg: X1, X2 Auxil wdg: Z1, Z2 M3 M5 L6 L9 VL12 0.24 0.215 0.185 0.19 0.17 0.4 0.36 0.36 0.32 0.32 After operational testing, it is essential to replace all access panels or covers. Field excitation current i exc (A) Symbols : “i exc”: excitation current of the exciter field LSA 46.2 No load At rated load M3 M5 L6 L9 VL12 1.1 1.1 1.1 1.2 1.1 4 3.8 4.1 4 3.5 For 60 Hz machines, the “i exc” values are approximately 5 to 10 % lower. 17 229/285 LEROY-SOMER Installation and maintenance 3856 en - 2011.01/ h LSA 46.2 - 4 POLES ALTERNATORS 5 - SPARE PARTS 5.1 - First maintenance parts Emergency repair kits are available as an option. They contain the following items: Emergency kit SHUNT AVR R 250 Diode bridge assembly Surge suppressor ALT 472 KS 001 - Emergency kit AREP AVR R 450 Diode bridge assembly Surge suppressor ALT 461 KS 001 - Single-bearing kit Non drive end bearing «O» ring Preloading (wavy) washer ALT 471 KB 002 - Double-bearing kit Non drive end bearing Drive end bearing «O» ring Preloading (wavy) washer ALT 471 KB 001 - 5.2 - Technical support service Our technical support service will be pleased to provide any additional information you may require. When ordering spare parts, you should indicate the complete machine type, its serial number and the information given on the nameplate. In the event of failure to comply with this advice, the manufacturer cannot be held responsible for any damage. 5.3 - Accessories 5.3.1 - Space heater for use when stopped The space heater must run as soon as the alternator stops. It is installed at the rear of the machine. Its standard power is 250W with 220V or 250W with 110V on request. Warning: the power supply is present when the machine has stopped. 5.3.2 - Temperature sensors with thermistors (PTC) These are thermistor triplets with a positive temperature coefficient installed in the stator winding (1 per phase). There can be a maximum of 2 triplets in the winding (at 2 levels: warning and trip) and 1 or 2 thermistors in the shields. These sensors must be linked to adapted sensing relays (supplied optionally). Cold resistance of cold thermistor sensors: 100 to 250 Ω per sensor. 5.3.3 - Connection accessories - 6-wire machines : coupling (F) - 12-wire machines : coupling (A), (F .F), (F) Address your enquiry to your usual contact. Part numbers should be identified from the exploded views and their description from the parts list. Our extensive network of service centres can dispatch the necessary parts without delay. After operational testing, it is essential to replace all access panels or covers. To ensure correct operation and the safety of our machines, we recommend the use of original manufacturer spare parts. 18 230/285 Installation and maintenance LEROY-SOMER 3856 en - 2011.01/ h LSA 46.2 - 4 POLES ALTERNATORS 5.4 - Exploded view, parts list and tightening torque 323 37 31 1 322 325 320 15 30 321 466 41 198 177 371 364 33 48 34 49 4 28 347 343 100 78 70 349 79 367 91 124 90 120 36 122 51 365 72 21 71 53 5.4.1 - LSA 46.2 single-bearing 19 231/285 Installation and maintenance LEROY-SOMER 3856 en - 2011.01/ h LSA 46.2 - 4 POLES ALTERNATORS 34 37 62 30 33 284 60 22 1 31 466 41 198 177 371 364 68 48 15 49 4 28 343 347 100 70 349 79 367 91 124 90 120 36 122 51 365 71 53 21 5.4.2 - LSA 46.2 double-bearing 20 232/285 LEROY-SOMER Installation and maintenance 3856 en - 2011.01/ h LSA 46.2 - 4 POLES ALTERNATORS Screw Torque Screw Torque Ref. Qty Description Ø N.m Ø N.m 1 1 Stator assembly 90 1 Exciter field 4 1 Rotor assembly 91 4 Fixing screws M6 10 15 1 Fan 100 1 Exciter armature 21 1 Lifting ring 120 1 Terminal plate support 22 1 Shaft extension key 122 1 Plate support 28 1 Earth terminal M10 20 124 1 Terminal plate M12 35 30 1 Drive end shield 177 2 AVR support bracket Voltage regulator 31 6 or 4 Fixing screws M14 80(*) 198 1 (AVR) 33 1 Protective grille 284 1 Circlips 34 2 Fixing screws M6 5 320 1 Coupling sleeve 36 1 Exciter end shield 321 1 Sleeve key 37 4 Fixing screws M12 50 322 3 Coupling disc 41 1 Cover front panel 323 6 Fixing screw M16 230 48 1 Cover top panel 325 - Spacer shim Diode bridge 49 Cover screws M6 5 343 1 M6 4 assembly Protection varistor 51 1 Air intake grille 347 1 (+ PCB) 53 1 Plug 349 1 “O” ring 60 1 Drive end bearing 364 1 AVR support 62 3 or 4 Fixing screws M8 20 365 1 Cover rear panel 68 1 Inner bearing retainer 367 2 Side panel 70 1 Non drive end bearing 371 4 Damper 71 1 Cover 416 1 Filter 72 2 Fixing screws M8 20 417 1 Filter support 78 1 Inner bearing retainer 466 2 AVR inspection door Preloading (wavy) 79 1 washer Ref. Qty Description (*) 80 N.m in M / 190 N.m in L, VL 21 233/285 LEROY-SOMER Installation and maintenance 3856 en - 2011.01/ h LSA 46.2 - 4 POLES ALTERNATORS Electric Power Generation Division Declaration of CE compliance and incorporation This Declaration applies to the generators designed to be incorporated into machines complying with the Machinery Directive Nr 2006/42/CE dated 17 May 2006. MOTEURS LEROY-SOMER Boulevard Marcellin Leroy 16015 ANGOULEME France MLS HOLICE STLO.SRO SLADKOVSKEHO 43 772 04 OLOMOUC Czech Republic MOTEURS LEROY-SOMER 1, rue de la Burelle Boite Postale 1517 45800 St Jean de Braye France Declares hereby that the electric generators of the types LSA 36 – 37– 40 – 42.2 – 43.2 – 44.2 – 46.2 – 47.2 – 49.1 – 50.2 – 51.2, as well as their derivatives, manufactured by Leroy Somer or on Leroy Somer's behalf, comply with the following International Standards and Directive : - EN and IEC 60034 -1 and 60034 -5 - ISO 8528 – 3 “ Reciprocating internal combustion engine driven alternating current generating sets. Part 3. Alternating current generators for generating sets ” - Low Voltage Directive Nr 2006/95/CE dated 12 December 2006. Furthermore, these generators, designed in compliance with the Machine Directive Nr 2006/42, are therefore able to be incorporated into Electrical Gen-Sets complying with the following International Directives : - Machinery Directive Nr 2006/42/CE dated 17 May 2006 - EMC Directive Nr 2004/108/CE dated 15 December 2004, as intrinsic levels of emissions and immunity are concerned WARNING : The here above mentioned generators should not be commissioned until the corresponding Gen-Sets have been declared in compliance with the Directives Nr 2006/42/CE et 2004/108/CE, as well as with the other relevant Directives. Leroy Somer undertakes to transmit, in response to a reasoned request by the national authorities, relevant information on the generator. Technical Managers P Betge – J.Begué 4152 en – 2010.11 / d 22 234/285 LEROY-SOMER Installation and maintenance 3856 en - 2011.01/ h LSA 46.2 - 4 POLES ALTERNATORS 23 235/285 LEROY-SOMER 16015 ANGOULÊME CEDEX - FRANCE 338 567 258 RCS ANGOULÊME www.leroy-somer.com 236/285 4067 en - 2009.05 / b STATOR : 12 wires (marking T1 to T12) MAIN FIELD T1 T7 T2 T8 T3 T4 T5 T11 T6 Varistor SHUNT SYSTEM 5+ Induced 6- Field T10 75 mm R 250 P1 Voltage ST4 Stability Option R250 A.V.R. Installation and maintenance 237/285 KNEE 65Hz LAM OFF KNEE 57Hz LAM OFF External potentiometrer for voltage adjusting 9 LAM OFF SPECIAL 8 7 50Hz o 901 6 1 23 P2 KNEE 47.5Hz 78 Slow fuse 250V 8 A 5 4 60Hz LAM OFF 2 3 13% 25% OFF 13% 25% LAM FREQ. & L.A.M. CONFIG. F1 456 n to give to be s i l er ua man e end us This th STAB VOLT 140 mm 110 0V E+ E- 4 x holes Ø 5.8 x 50 x 115 mm Frequency selector 50 H / 60 Hz for U/F fonction and LAM adjustement LEROY-SOMER Installation and maintenance R250 4067 en - 2009.05 / b A.V.R. This manual concerns the alternator A.V.R. which you have just purchased. We wish to draw your attention to the contents of this maintenance manual. By following certain important points during installation, use and servicing of your A.V.R., you can look forward to many years of trouble-free operation. SAFETY MEASURES WARNING Before using your machine for the first time, it is important to read the whole of this installation and maintenance manual. All necessary operations and interventions on this machine must be performed by a qualified technician. Warning symbol for an operation capable of damaging or destroying the machine or surrounding equipment. Our technical support service will be pleased to provide any additional information you may require. The various operations described in this manual are accompanied by recommendations or symbols to alert the user to potential risks of accidents. It is vital that you understand and take notice of the following warning symbols. Warning symbol for general danger to personnel. Warning symbol for electrical danger to personnel. Note : LEROY-SOMER reserves the right to modify the characteristics of its products at any time in order to incorporate the latest technological developments. The information contained in this document may therefore be changed without notice. 2 238/285 LEROY-SOMER Installation and maintenance R250 4067 en - 2009.05 / b A.V.R. SUMMARY 1 - SUPPLY...............................................................................................................................4 1.1 - SHUNT excitation system.............................................................................................4 2 - R250 A.V.R..........................................................................................................................5 2.1 - Characteristics.............................................................................................................. 5 2.2 - U/F fonction and LAM....................................................................................................5 2.3 - R250 A.V.R. option........................................................................................................ 5 2.4 - LAM Characteristics .....................................................................................................6 2.5 - Typical effects of the LAM..............................................................................................7 3 - INSTALLATION - COMMISIONING....................................................................................8 3.1 - Electrical checks on the AVR.........................................................................................8 3.2 - Settings.........................................................................................................................8 3.3 - Electrical faults.............................................................................................................. 9 4 - SPARE PARTS.................................................................................................................. 10 4.1 - Designation.................................................................................................................10 4.2 - Technical support service............................................................................................10 Any maintenance or breakdown operations on the A.V.R. are to be done by personnel trained on commisioning, servicing and maintenance for the electrical and mechanical elements. The R250 is an IP00 product. It must be installed inside a unit so that this unit’s cover can provide IP20 minimum total protection (it must only be installed on LS alternators in the appropriate location so that when viewed externally, it has a higher degree of protection than IP20). Copyright 2005: MOTEURS LEROY-SOMER This document is the property of: MOTEURS LEROY SOMER. It may not be reproduced in any form without prior authorization All brands and models have been registered and patents applied for. 239/285 3 LEROY-SOMER Installation and maintenance 4067 en - 2009.05 / b R250 A.V.R. 1 - SUPPLY 1.1 - SHUNT excitation system The regulator controls the excitation current according to the alternator’s output voltage. With a very simple conception, the SHUNT excitation alternator does not have a short circuit capacity. The SHUNT excitation alternator is autoexcited with a R 250 voltage regulator. STATOR : 12 wires (marking T1 to T12) MAIN FIELD T1 T7 T2 T8 T3 T9 T4 T10 T5 T11 T6 T12 Varistor SHUNT SYSTEM 5+ Induced 6- Field 75 mm R 250 Voltage ST4 9 LAM OFF SPECIAL KNEE 65Hz LAM OFF KNEE 57Hz LAM OFF 8 7 50Hz o 901 6 5 4 60Hz Option External potentiometrer for voltage adjusting 4 1 23 P2 Stability KNEE 47.5Hz 78 P1 456 Slow fuse 250V 8 A 240/285 LAM OFF 2 3 13% 25% OFF 13% 25% LAM FREQ. & L.A.M. CONFIG. F1 STAB VOLT 140 mm 110 0V E+ E- 4 x holes Ø 5.8 x 50 x 115 mm Frequency selector 50 Hz / 60 Hz for U/F fonction and LAM adjustement Installation and maintenance LEROY-SOMER R250 4067 en - 2009.05 / b A.V.R. 2 - R250 A.V.R. 2.1 - Characteristics The threshhold position and LAM fonction settings are done with the jumper. -Storage: -55°C; +85°C -Operation: -40°C; +70°C -Voltage regulation: around ± 0,5 %. -Supply range/voltage detection 85 to 139 V (50/60Hz). -Rapid response time (500 ms) for a transient voltage variation amplitude of ± 20 %. -Voltage setting P1. -Stability setting P2. -Power supply protected by 8 A fuse, replacement product: Ferraz-Shawmut T084013T fast-blow fuse, 8 A FA 250 V, breaking capacity 30 kA. The threshold position (50 Hz - 60 Hz) to action the U/F fonction as well as the LAM setting type is selected using the potentionmeter. 50Hz KNEE LAM OFF KNEE 57Hz LAM OFF 7 78 65Hz 901 6 5 OFF 13% 2 3 4 60Hz 1: threshold at 48 Hz with LAM 13% for impacts between 40 and 70% of the rated load. 2: threshold at 48 Hz with LAM 25% for impacts > 70% of the rated load. Operating at 60 Hz: (U/F gradient) 3: threshold at 58 Hz without LAM for impacts between 30 and 40% of the rated load. 5: threshold at 58Hz with LAM 25% for impacts > 70% of the rated load. Specific operating 6: threshold at 57Hz without LAM for speed variations at a steady state > 2 Hz LAM 1 23 KNEE 8 456 SPECIAL o 9 LAM OFF 0: threshold at 48 Hz without LAM for impacts between 30 and 40% of the rated load. 4: threshold at 58Hz with LAM 13% for impacts 40 and 70% of the rated load. 2.2 - U/F Fonction and LAM 47.5Hz Operating at 50 Hz: (U/F gradient) 7: threshold at 65Hz without LAM for variable speed and tractelec / gearlec (U/F gradient). 25% OFF 13% 8: special: the factory setting 48Hz 2U/F gradient ; a special programme is possible on request. This programme must be specified before ordering, during the project study. 25% LAM WARNING: The jumper settings must correspond to the rated operating frequency (see the nameplate on the alternator). Risk of destruction for the alternator. 241/285 9: threshold at 47.5 Hz without LAM for speed variations at a steady state > 2 Hz. For hydraulic applications, it is advisable to select: - position 0 for 50 Hz - position 3 for 60 Hz 5 LEROY-SOMER Installation and maintenance 4067 en - 2009.05 / b R250 A.V.R. 2.3 - R250 A.V.R. option Potentiometer for voltage setting, 1000 W / 0,5 W min: setting range ± 5 %. - Remove the ST4 jumper. It is advised to use the “LAM” at 25% for load impacts > at 70% of the genset rated power. Voltage Voltage UN 0,85 UN For wiring up the external potentiometer; the “earth” wires must be isolated as well as the potentiometer terminals (wires at the same voltage as the power). 2.4 - LAM characteristics (Load Acceptance Module) 2.4.1 - Voltage drop The LAM system is integrated in the A.V.R. It is active as standard. It can be adjusted to 13% or 25%. - Role of the «LAM» (Load Adjustment Module): On application of a load, the rotation speed of the generator set decreases. When it passes below the preset frequency threshold, the LAM causes the voltage to drop by approximately 13% or 25% and consequently the amount of active load applied is reduced by approximately 25% to 50%, until the speed reaches its rated value again. Hence the “LAM” can be used either to reduce the speed variation (frequency) and its duration for a given applied load, or to increase the applied load possible for one speed variation (turbo-charged engines). To avoid voltage oscillations, the trip threshold for the “LAM” function should be set approximately 2 Hz below the lowest frequency in steady state. 6 0 U/f LAM 48 or 58 Hz ST3 fC 50 or 60 Hz fN 2.4.2 - Gradual voltage return function During load impacts, the function helps the genset to return to its rated speed faster thanks to a gradual increase in voltage according to the following principles: - if the speed drops between 46 Hz and 50 Hz, the rated voltage follows a fast gradient as it is restored. - if the speed drops below 46 Hz, since the engine needs more help, the voltage follows a slow gradient as it returns to the reference value. U Drop N < 46 Hz 0 242/285 Drop N > 46 Hz Time Installation and maintenance LEROY-SOMER R250 4067 en - 2009.05 / b A.V.R. 2.5 - Typical effects of the LAM with a diesel engine or without a LAM (U/F only) 2.5.1 - Voltage Transient voltage drop UN 0,9 (U/f) without LAM with LAM 0,8 1s 0 Time 2s 3s 2.5.2 - Frequency Max speed drop fN with LAM 0,9 without LAM 0,8 1s 0 2s Time 3s 2.5.3 - Power Load on shaft (kW) LAM 0 Load variation Shedding due to "LAM" 1s 2s Time 3s 243/285 7 LEROY-SOMER Installation and maintenance R250 4067 en - 2009.05 / b A.V.R. 3 - INSTALLATION COMMISSIONING 3.1 - Electrical checks on the AVR - Check that all connections have been made properly as shown in the attached wiring diagram. - Check that the position of the jumper corresponds to the operating frequency. - Check whether the ST4 jumper or the remote adjustment potentiometer have been connected. 3.2.2 - Special type of use WARNING Excitation circuit E+, E- must not be left open when the machine is running: A.V.R. damage will occur. 3.2.2.1 - R250 field weakening (SHUNT) The different settings made during the trial are to be done by qualified personnel. Respecting the load speed specified on the nameplate is vital in order to start a settings procedure. After operational testing, replace all access panels or covers. The only possible settings on the machine are to be done with the A.V.R. 110 0V E+ E- 3.2 - Settings The exciter is switched off by disconnecting the A.V.R. power supply (1 wire - 0 or 110V). Contact rating: 16A - 250V AC Do not reclose the power supply until the voltage has reached a value ≤15% of the rated voltage (approximately 5 seconds after opening) 3.2.2.2 - R250 field forcing (400V - 10A) t Initial potentiometer positions - voltage setting potentiometer P1 for the A.V.R.: full left - remote voltage setting potentiometer: in the middle. Operate the alternator at its rated speed: if the voltage does not rise it is necessary to re-magnatise the magnetic circuit. - slowly adjust the voltage potentiometer of the A.V.R. P1 until the output voltage reaches its rated value. - Stability setting with P2. 110 0V E+ E- 3.2.1 - R250 settings (SHUNT system) Diode - Battery (B Volt) Excitation Inducer The battery must be isolated from the mass. Exciter field may be at line potential. 8 + 244/285 LEROY-SOMER Installation and maintenance R250 4067 en - 2009.05 / b A.V.R. 3.3 - Electrical faults Fault Action Connect a new battery No voltage at of 4 to 12 volts to no load on terminals E- and E+ start-up respecting the polarity for 2 to 3 seconds Voltage too low Effect - Lack of residual magnetism The alternator starts up but its voltage disappears when the battery is removed - Faulty A.V.R. - Exciter field short-circuited - Short-circuit in the main field. Check the resistance The alternator starts up but its voltage does not reach the rated value when the battery is removed. Correct speed Check the drive speed Speed too low Voltage too high Adjust A.V.R. potentiometer Voltage oscillations Adjust A.V.R. stability potentiometer Voltage correct at no load and too low when on load (*) Run at no load and check the voltage between E+ and E- on the A.V.R. Check/cause The alternator starts up and its voltage is still correct when the battery is removed. Adjustment ineffective - Check the connection of the voltage reference to the A.V.R. - Faulty diodes - Induced short circuit Check the A.V.R. connections (A.V.R. may be faulty) - Field windings short-circuited - Rotating diodes burnt out - Main field winding short-circuited - Check the resistance Increase the drive speed (Do not touch the A.V.R. pot (P1) before returning to the correct speed.) - Faulty A.V.R. - 1 faulty diode - Check the speed: possibility of cyclic irregularity - Loose terminals - Faulty A.V.R. - Speed too low on load (or U/F gradient set too high) - Check the speed (or U/F gradient set too high) - Faulty rotating diodes - Short-circuit in the main field. Check the resistance - Faulty induced excitaion (*) Warning: For single-phase operation, check that the sensing wires coming from the A.V.R. are correctly connected to the operating terminals (see the alternator manual). Voltage disappears during operation Check the A.V.R., the surge suppressor, the rotating diodes and replace any defective components - Exciter winding open circuit The voltage does not return to the - Faulty induced excitation rated value - Faulty A.V.R. - Main field open circuit or short-circuited Warning: after setting-up or troubleshooting, replace all access panels or covers. 245/285 9 Installation and maintenance LEROY-SOMER R250 A.V.R. 4 - SPARE PARTS 4.1 - Designation Description A.V.R. Type R 250 Code AEM 110 RE 019 4.2 - Technical support service Our technical support service will be pleased to help you with any information needed. For replacement part orders, it is necessary to indicate the type and the code number of the A.V.R. Please contact your usual correspondant. An extensive network of service centres is available to rapidly supply any necessary parts. In order to ensure the correct operation and safety of our machines, we strongly recommend that original manufacturer’s spare parts are used. Failure to do so, will discharge the manufacturer from liabilty in the case of damage. 10 246/285 4067 en - 2009.05 / b LEROY-SOMER Installation and maintenance R250 4067 en - 2009.05 / b A.V.R. 247/285 11 MOTEURS LEROY-SOMER 16015 ANGOULÊME CEDEX - FRANCE 338 567 258 RCS ANGOULÊME S.A. au capital de 62 779 000 ¤ www.leroy-somer.com 248/285 3 LAM OFF LAM MODE 1 LAM MODE 2 LAM OFF LAM MODE 1 LAM STAB. I EXC 1 4 2 50Hz 0 90 1 23 6 4 56 VOLT. 7 8 EXT.FREQ. SET. 9 LAM ON LAM OFF KNEE ONLY FOR SPECIAL CONFIG. SERIES 0 SERIES 0 LSA 46.2/47.2 5000/6000 LSA 46.2/47.2 1 5000/6000 LEDS FUSIBLES / FUSES Installation & maintenance manual : www.leroy-somer.com VOIR NOTICE SEE NOTICE Installation and maintenance 5 MODE 2 65Hz LAM OFF 60Hz 1 PHASE SENSING 2 3 STAT. AVRs SERIES 3 7000/8000 2 SERIES 7000/8000 LSA 49.1/50.2 S2 R 450 US C X2 Z1 E+ Z2 X1 E- 1 380V 220 110 0V LSA 49.1/50.2 0 1 NORMAL 1 NORMAL 0 NORMAL NORMAL 3 PAHASES SENSING SHUNT / AREP 3 S1 249/285 PMG 1k n to RAPIDE 3 FAST RAPIDE FAST 2 3PH. ive be g o t s er ual i man e end us h This t 50 Hz EXT FREQ 60 Hz SETTING R 450 78 2 4531 en - 2012.03 / e LEROY-SOMER Installation and maintenance 4531 en - 2012.03 / e R 450 AVRs This manual concerns the alternator AVR which you have just purchased. We wish to draw your attention to the contents of this maintenance manual. By following certain important points during installation, use and servicing of your AVR, you can look forward to many years of trouble-free operation. SAFETY MEASURES Before using your machine for the first time, it is important to read the whole of this installation and maintenance manual. WARNING All necessary operations and interventions on this machine must be performed by a qualified technician. Warning symbol for an operation capable of damaging or destroying the machine or surrounding equipment. Our technical support service will be pleased to provide any additional information you may require. The various interventions described in this manual are accompanied by recommendations or symbols to alert the user to potential risks of accidents. It is vital that you understand and take notice of the various warning symbols used. Warning symbol for general danger to personnel. Warning symbol for electrical danger to personnel. Note: LEROY-SOMER reserves the right to modify the characteristics of its products at any time in order to incorporate the latest technological developments. The information contained in this document may therefore be changed without notice. 2 250/285 LEROY-SOMER Installation and maintenance 4531 en - 2012.03 / e R 450 AVRs CONTENTS 1 - GENERAL INFORMATION ................................................................................................4 1.1 - Description.................................................................................................................... 4 1.2 - Characteristic................................................................................................................ 4 2 - POWER SUPPLY................................................................................................................ 5 2.1 - AREP excitation system................................................................................................5 2.2 - PMG excitation system..................................................................................................6 2.3 - SHUNT or separate excitation system...........................................................................7 3 - TECHNICAL CHARACTERISTICS.....................................................................................8 3.1 - Electrical characteristics................................................................................................8 3.2 - Configurations............................................................................................................... 8 3.3 - U/F and LAM functions................................................................................................12 3.4 - Typical effects of the LAM with a diesel engine with or without a LAM (U/F only)......... 12 3.5 - AVR options . .............................................................................................................. 13 4 - INSTALLATION - COMMISSIONING................................................................................14 4.1 - Electrical checks on the AVR.......................................................................................14 4.2 - Setting up.................................................................................................................... 14 4.3 - Electrical faults............................................................................................................ 17 5 - SPARE PARTS.................................................................................................................. 18 5.1 - Designation................................................................................................................. 18 5.2 - Technical support service............................................................................................18 All servicing or repair operations performed on the AVR should be undertaken by personnel trained in the commissioning, servicing and maintenance of electrical and mechanical components. Copyright 2005: LEROY-SOMER MOTORS This document is the property of: LEROY-SOMER It may not be reproduced in any form without prior authorization. All brands and models have been registered and patents applied for. 3 251/285 LEROY-SOMER Installation and maintenance 4531 en - 2012.03 / e R 450 AVRs 1 - GENERAL INFORMATION 1.1 - Description 1.2 - Characteristic The connection is realised by “Faston” connectors and the voltage sensing is single - phase. The R450 AVR is supplied in a casing designed to be mounted on a panel with dampers. - Operating temperature: - 30°C to + 65° C. - Storage temperature: - 55°C to + 85°C. - Shocks on the base: 9 g depending on the 3 axes. - Vibrations: less than 10 Hz, 2 mm half-peak amplitude 10 Hz to 100 Hz: 100 mm/s, above 100 Hz: 8 g. WARNING The AVR is IP00, it must be incorporated in an environment which ensures it a IP20 protection. 140 mm 115 mm 4 holes Ø 6.5 mm R 450 4 56 23 1 4 2 3 50Hz 0 5 LAM OFF LAM MODE 1 LAM MODE 2 LAM OFF LAM MODE 1 LAM MODE 2 0 SERIES 1 SERIES 0 LSA 46.2/47.2 5000/6000 LSA 46.2/47.2 1 5000/6000 STAB. I EXC 78 90 1 2 VOLT. EXT.FREQ. SET. 9 8 7 0 2 50 Hz 60 Hz LAM ON LAM OFF ONLY FOR SPECIAL CONFIG. 6 3 3 0 NORMAL NORMAL 1 S1 NORMAL 1 NORMAL 1 PHASE SENSING KNEE 65Hz LAM OFF SERIES 7000 /8000 LSA 49.1 /50.2 SERIES 7000 /8000 2 LSA 49.1 /50.2 3 PMG 1k 3 PAHASES SENSING SHUNT / AREP RAPIDE 3 FAST RAPIDE FAST 2 3PH. Rotating switch - Lam and U/F - Voltage - Excitation 50 Hz EXT FREQ 60 Hz SETTING FUSIBLES / FUSES 200 mm Installation & maintenance manual : www.leroy-somer.com Quad droop LEDS STAT. 175 mm S2 P4 VOIR NOTICE SEE NOTICE 380V 220 110 0V E- E+ Z2 X1 Z1 X2 4 252/285 C US P1 Voltage P2 Stability P3 Excitation Overrun indications Fuses 10A LEROY-SOMER Installation and maintenance 4531 en - 2012.03 / e R 450 AVRs 2 - POWER SUPPLY characteristic), the second one has a voltage proportional to the stator current (compound characteristic : Booster effect). The power supply voltage is rectified and filtered before being used by the AVR monitoring transistor. This system provides the machine with a short-circuit current capacity of 3 IN for 10 s. The rotating switch should be in the AREP position (see 3.2.3). Both the SHUNT/AREP & PMG excitation systems are controlled by the AVR. 2.1 - AREP excitation system With AREP excitation, the electronic AVR is powered by two auxiliary windings which are independent of the voltage sensing circuit. The first winding has a voltage proportional to the alternator main voltage (Shunt STATOR : 6 wires ( T1 to T6) STATOR : 12 wires ( T1 to T12) MAIN FIELD AREP SYSTEM Aux. windings T1 T7 T8 T3 T9 T11 T6 T12 R 450 T5 50 Hz EXT FREQ 60 Hz SETTING 4 56 1 2 3 50Hz 0 4 LAM OFF LAM MODE 1 LAM MODE 2 LAM OFF LAM MODE 1 LAM 0 SERIES 1 SERIES 0 LSA 46.2/47.2 5000/6000 LSA 46.2/47.2 1 5000/6000 STAB. I EXC 78 90 1 2 VOLT. 8 7 6 EXT.FREQ. SET. 9 LAM ON LAM OFF ONLY FOR SPECIAL CONFIG. KNEE LAM OFF 3 3 0 0 NORMAL NORMAL 1 NORMAL 1 NORMAL S1 5 MODE 2 65Hz 60Hz 1 PHASE SENSING SERIES 7000 /8000 LSA 49.1 /50.2 SERIES 7000 /8000 2 LSA 49.1 /50.2 3 PMG 1k 3 PAHASES SENSING SHUNT / AREP RAPIDE 3 FAST RAPIDE FAST 2 3PH. 2 T4 T10 9 Green Field 11 Red 6- 10 Yellow Armature 23 5+ 12 Black Varistor T2 S2 LEDS STAT. FUSIBLES / FUSES Installation & maintenance manual : www.leroy-somer.com VOIR NOTICE SEE NOTICE 380V 220 110 0V E- E+ Z2 X1 Z1 X2 according to voltage C US 10 Yellow 11 Red 12 Black 9 Green 5 253/285 LEROY-SOMER Installation and maintenance 4531 en - 2012.03 / e R 450 AVRs 2.2 - PMG excitation system The AVR monitors the alternator output voltage by adjusting the excitation current. The rotating switch should be in the PMG position (see 3.2.3). With PMG excitation, a permanent magnet generator (PMG) added to the alternator supplies the AVR with voltage which is independent of the main alternator winding. This system provides the machine with a short-circuit current capacity of 3 IN for 10 s. STATOR : 6 wires ( T1 to T6) STATOR : 12 wires ( T1 to T12) MAIN FIELD PMG SYSTEM T1 T7 T2 T8 T3 T9 T11 T6 T12 Varistor Armature PMG 5+ Field 6- T4 T10 R 450 16 15 50 Hz EXT FREQ 60 Hz SETTING 14 0 2 4 56 23 2 3 STAB. I EXC 1 4 LAM OFF LAM MODE 1 LAM MODE 2 LAM OFF LAM MODE 1 LAM MODE 2 SERIES 1 SERIES 0 LSA 46.2/47.2 5000/6000 LSA 46.2/47.2 1 5000/6000 50Hz 0 5 90 1 0 2 VOLT. 8 7 EXT.FREQ. SET. 9 LAM ON LAM OFF ONLY FOR SPECIAL CONFIG. 6 3 3 0 NORMAL NORMAL 1 S1 NORMAL 1 NORMAL 60Hz 1 PHASE SENSING KNEE LAM OFF 65Hz SERIES 7000 /8000 LSA 49.1 /50.2 SERIES 7000 /8000 2 LSA 49.1 /50.2 3 PMG 1k 3 PAHASES SENSING SHUNT / AREP RAPIDE 3 FAST RAPIDE FAST 2 3PH. 78 S2 LEDS STAT. FUSIBLES / FUSES Installation & maintenance manual : www.leroy-somer.com VOIR NOTICE SEE NOTICE 380V 220 110 0V E- E+ Z2 X1 Z1 X2 according to voltage 16 15 6 254/285 14 C US T5 LEROY-SOMER Installation and maintenance 4531 en - 2012.03 / e R 450 AVRs 2.3 - SHUNT or separate excitation system With SHUNT excitation, the AVR is powered by the main winding (100V to 140V 50/60 Hz ) by using X1, X2 on the AVR. The rotating switch should be in the SHUNT/ AREP position (see 3.2.3). STATOR : 6 wires ( T1 to T6) STATOR : 12 wires ( T1 to T12) MAIN FIELD SHUNT SYSTEM T1 T7 T2 T8 T3 T9 Varistor Armature 6- T4 T10 R 450 T11 T6 T12 4 56 1 2 3 50Hz 0 4 LAM OFF LAM MODE 1 LAM MODE 2 LAM OFF LAM MODE 1 LAM SERIES 1 SERIES 0 LSA 46.2/47.2 5000/6000 LSA 46.2/47.2 1 5000/6000 STAB. I EXC 78 90 1 2 VOLT. 8 7 6 EXT.FREQ. SET. 9 LAM ON LAM OFF ONLY FOR SPECIAL CONFIG. KNEE LAM OFF 3 3 0 0 NORMAL NORMAL 1 NORMAL 1 NORMAL S1 5 MODE 2 65Hz 60Hz 1 PHASE SENSING SERIES 7000 /8000 LSA 49.1 /50.2 SERIES 7000 /8000 2 LSA 49.1 /50.2 3 PMG 1k 3 PAHASES SENSING SHUNT / AREP RAPIDE 3 FAST RAPIDE FAST 2 3PH. 2 T5 50 Hz EXT FREQ 60 Hz SETTING 0 Field 23 5+ S2 LEDS STAT. FUSIBLES / FUSES Installation & maintenance manual : www.leroy-somer.com VOIR NOTICE SEE NOTICE 380V 220 110 0V E- E+ Z2 X1 Z1 X2 C US X1 X2 7 255/285 LEROY-SOMER Installation and maintenance 4531 en - 2012.03 / e R 450 AVRs 3 - TECHNICAL CHARACTERISTICS 3.1 - Electrical characteristics - maximum power supply: 150V - 50/60 Hz - Rated overload current: 10 A - 10 s - Electronic protection: - In the case of a short-circuit, the excitation current is reduced to a value less than 1A after 10 s - In the event of loss of voltage reference, the excitation current is reduced to a value less than 1A after 1s for AREP/SHUNT, 10 s for PMG. - In the event of overexcitation, the current is reduced as indicated in the next diagram (see 3.2.1.4). - Fuses: F1 on X1 and F2 on Z2 10A, 250V. - Voltage sensing • 0-110 V terminals = 95 to 140 V • 0-220 V terminals = 170 to 260 V • 0-380 V terminals = 340 to 528 V For other voltages, a transformer should be used. - Voltage regulation:± 0.5%. - Current sensing: (parallel operation): input S1, S2 intended for 1 C.T. < 2.5 VA cl1, secondary 1 A or 5 A. 3.2 - Configurations: 3.2.1 - Settings 3.2.1.1 - Voltage Voltage adjustment via potentiometer P1 in the ranges described in the table below: For 50 and 60 Hz High range Low range Max. 320V < Un ≤ 530 V 80 V ≤ Un ≤ 320 V WARNING The allowed adjustment range is ±5%; when the setting exceeds these limits, please check that it is conform with the power table. 3.2.1.2 - Quadrature droop: Quadrature droop adjustment via potentiometer P4 within a range : - from 0 to 8% with a PF=0.8 for 400V applications. - From 0 to 14% with a PF=0.8 for 240V applications. - From 0 to 8% for 110V applications with a step-up transformer (ratio of 4) placed on the voltage reference. The potentiometer P4 has a non linear response. Then, when a 1A secondary CT is connected the effective range starts from the the second 1/3 of P4 range and in the case of a 5A secondary CT the effective range starts from the first 1/3. When a 5A CT is used, the adjustment range is higher, so P4 must be set to the first 1/4 (anti-clockwise) and then progressively increase it. WARNING The CT must be connected. 3.2.1.3 - Stability: Stability adjustment via potentiometer P2. Selection of rotating switch according to the machine type and the response time as indicated in paragraph 3.2.3. 3.2.1.4 - Excitation limitation: Excitation limitation adjustment via potentiometer P3 as described below. The excitation current limitation threshold in steady state is set by a potentiometer at 110% of the rated value. The adjustment is made by the operator during the on-load test at rated power by tuning the potentiometer. When the excitation current exceeds this value, a counter is activated at the speed of one record per second for 90 s. When this time is elapsed, the current is reduced to the value of the rated excitation current. If in the meantime the excitation current drops below the threshold value, the counter counts down at the same speed. 8 256/285 LEROY-SOMER Installation and maintenance 4531 en - 2012.03 / e R 450 AVRs excitation current must be limited to 9 A ± 0.5 A. WARNING The limitation threshold must be adjustable between 1 and 5.5 A. The genset breaker must be open during the short circuit. If the genset is restarted in short circuit, there is a excitation build up during 10s again at the maximum value. Operation between 3 and 6 In when short-circuited: The excitation current ceiling during a short-circuit equals 2.9 times the fixed threshold when setting the permitted excitation ceiling in continuous operation. When the threshold is exceeded for a period = 10 s the current is reduced to a value between 0.5 and 0.7 A (shutdown). In all operating conditions the maximum Overrun indications: One green LED: - Lights up when the excitation current is below the continuous operation threshold It signals the AVR normal operation. - Turns off when the excitation current ceiling used to obtain short-circuit operation is reached and when the excitation current is reduced to the shutdown value. - Flashes when the over excitation counter is decrementing. NB: After an obvious short-circuit, the voltage is limited to 70% of the rated voltage. This avoids overvoltages on machines whose no-load excitation current is below the “lower current” threshold (only in AREP). I exc(A) 2.9x I threshold (max. 9.5 A) 9.5 Diagram 1 (Maximum current I exc) P3 I threshold (1...5.5A) Shutdown 0.5 ~ 0.7 t(s) Activation of 90 s tempo. Decrease of 90 s tempo. Activation of 90 s tempo. Activation of 10 s tempo. 10s tempo. elapsed : shutdown apllication Red led Green led 9 257/285 LEROY-SOMER Installation and maintenance 4531 en - 2012.03 / e R 450 AVRs I exc(A) 2.9x I threshold (max. 9.5 A) 9.5 Diagram 2 (Maximum current I exc) P3 I threshold (1...5.5A) Shutdown 0.5 ~ 0.7 t(s) Activation of 90 s. tempo 90 s. tempo elapsed : application of permanent limitation Red led Green led One red LED: - Lights up simultaneously with the green led when the continuous operation threshold is reached for more than 90 s and the excitation current is reduced to the continuous operation threshold. It is used to set the excitation current ceiling - Turns off when the excitation current is less than the setting value (< 110% In) - Flashes when the excitation current is above the continuous operation threshold during less than 90 s. Green LED stays on, - flashes when the excitation current has reached the ceiling in < 10s with PMG excitation. - ftays on if Iexc = I Shutdown. WARNING If the overload protection is activated, a voltage drop possibly exceeding 10% of the reference voltage will be observed. The AVR does not provide undervoltage protection. The customer will need to make sure that their installation is correctly protected against undervoltages. During load shedding, an overvoltage is observed, which will disappear in a few seconds. 10 258/285 LEROY-SOMER Installation and maintenance 4531 en - 2012.03 / e R 450 AVRs KNEE 65Hz LAM OFF 78 456 7 6 2 5 3 4 60Hz RAPIDE 3 FAST RAPIDE FAST 2 For Pavers and hydraulic applications, select positions 0 (50 Hz) or 3 (60 Hz). 0 NORMAL NORMAL PMG NORMAL 1 NORMAL 0: AREP excitation and normal time response. 3: AREP excitation and fast time response. 1: PMG excitation and normal time response. 2: PMG excitation and fast time response. For SHUNT applications, AREP excitation must be selected. 3.2.4 Rotating switch: voltage sensing 1 PHASE SENSING SERIES LSA 49.1/50.2 7000/8000 3 SERIES LSA 49.1/50.2 SERIES 3 0 LSA 46.2/47.2 5000/6000 1 WARNING 3 0 - Pos 0: Change in the voltage according to the U/F ratio, knee-point position at 48 Hz. - Pos 1: Change in the voltage according to the 2U/F, knee-point position at 48 Hz. - Pos 2: Change in the voltage according to the self auto-adaptating LAM combined with 2U/F, knee-point position at 48 Hz. - Pos 3: Change in the voltage according to the U/F ratio, knee-point position at 58 Hz - Pos 4: Change in the voltage according to the 2U/F, knee-point position at 58 Hz. - Pos 5: Change in the voltage according to the self auto-adaptating LAM combined with 2U/F, knee-point position at 58 Hz. - Pos 6: Change in the voltage according to the U/F ratio, knee-point position at 65 Hz (Tractelec application and variable speed above 1800 rpm). - Pos 7: Special (not used). - Pos 8: Change in the voltage according to the U/F ratio, knee-point position at 48 Hz or 58 Hz according to selection of the frequency by an external contact. - Pos 9: Change in the voltage according to LAM 1, knee-point position at 48 Hz or 58 Hz according to selection of the frequency by an external contact AREP 1 ONLY FOR SPECIAL CONFIG. 1 LAM OFF LAM MODE 1 LAM MODE 2 LAM OFF LAM MODE 1 LAM MODE 2 0 8 901 23 LAM OFF 50Hz 0 2 EXT.FREQ. LAM SET. 9 ON 3.2.3 Rotating switch: excitation type and time response 2 3.2.2 - Rotating switch selection: LAM and U/F 7000/8000 2 SERIES LSA 46.2/47.2 1 5000/6000 ONLY WITH EXTERNAL R731 MODULE 3 PHASES SENSING 0: Single phase sensing - LSA46.2/47.2 series. 3: Single phase sensing - LSA49.1/50.2 series. 1: Three-phase sensing with optional module R731 - LSA46.2/47.2 series. 2: Three-phase sensing with optional module R731 - LSA49.1/50.2 series. 11 259/285 LEROY-SOMER Installation and maintenance 4531 en - 2012.03 / e R 450 AVRs 3.3 - U/F and LAM function 3.3.1 - Frequency variation compared with voltage (without LAM) Bend Voltage 48 Hz 100 % U/UN 57.5 Hz 50 Hz 60 Hz Frequency 50 Hz 60 Hz Hz 3.3.2.2 - Soft voltage recovery function During load impacts, the function helps the genset to return to its rated speed faster with a gradual increase in voltage according to the principle: - If the speed drops between 46 and 50 Hz (in 50Hz operation), the rated voltage is recovered by following a fast gradient. - If the speed drops below 46 Hz, since the engine needs more help, the voltage follows a slow gradient as it returns to the reference value. 3.3.2 - LAM (Load Acceptance Module) characteristics 3.3.2.1 - Voltage drop The LAM system is integrated in the AVR. As standard it is active. Role of the LAM: On application of a load, the genset rotation speed decreases. When it falls below the preset frequency threshold, the LAM causes the voltage to drop proportionately to the frequency (LAM1) or to the active power (LAM2) depending the the rotating switch position. This reduces the active load scale applied until the speed returns to its rated value. Hence the LAM can be used either to reduce the speed variation (frequency) and its duration for a given applied load, or to increase the applied load possible for one speed variation (turbo-charged engine). To avoid voltage oscillations, the trip threshold for the LAM function should be set approximately 2 Hz below the rated frequency. U Drop N 46 Hz Drop N > 46 Hz 3.4 - Typical effects of the LAM with a diesel engine with or without a LAM (U/F only) 3.4.1 - Voltage 0,9 (U/f) without LAM with LAM 0,8 Time 1s 0 2s 3s 3.4.2 - Frequency Max. speed drop with LAM Voltage UN 0,9 U/f LAM 0,85 UN 0 Transient voltage drop UN fN Voltage Time 0 without LAM 0,8 0 48 or 58 Hz ST3 fC 50 or 60 Hz fN 12 260/285 1s 2s Time 3s LEROY-SOMER Installation and maintenance 4531 en - 2012.03 / e R 450 AVRs 3.4.3 - Power • Equalization of voltages before paralleling (3 F). • Possibility of coupling to the mains of alternators already running in parallel (4F). Load on the shaft (kW) LAM 0 -R729 module: same as R726 with additional functions. • Detection of a diode fault. • 4-20 mA input. • Possibility of kVAR regulation. Variation in the load Load shedding due to LAM 1s 2s Time 3s 3.5 - AVR options - Current transformer for parallel operation of....../1 A or 5 A according to the potentiometer P4 position. -Voltage transformer (adaptation) -Voltage control: with an isolated D.C. current source applied to the terminals used for the external potentiometer: • Internal impedance 1.5 kΩ. • A variation of ± 0.5 V corresponds to a voltage adjustment of ± 10%. -Remote voltage adjustment potentio meter. For a range of variation: ± 5% : 470 Ω ± 10% : 1 kΩ the power of the potentiometer can be 0.5 W, 2 W or 3 W. The potentiometer input must be isolated. Do not connect it to the ground. -R 731 module: 3-phase voltage sensing 200 to 500 V, compatible with parallel operation in balanced installations. -R 734 module: 3-phase current and voltage sensing for parallel operation on unbalanced installations (unbalance > 15%). - R 726 module: regulation system changed to “4 - function” (see the maintenance manual and connection diagram). • PF regulation (2F) . 13 261/285 LEROY-SOMER Installation and maintenance 4531 en - 2012.03 / e R 450 AVRs 4-INSTALLATION-COMMISSIONING 4.1 - Electrical checks on the AVR - Check that all connections have been made properly as shown in the attached wiring diagram. - Check the rotating switches selections - frequency, - type of alternator, - normal position (response time), - external potentiometer, - rated voltage, - secondary current of the CT used, - type of excitation. - R450 optional operating modes 4.2 - Setting up Factory setting Pot. Voltage minimum fully anti-clockwise Action 400 V - 50 Hz P1 Stability Not set (centre position) P2 Excitation ceiling - Factory-sealed 10 A maximum P3 Voltage quadrature droop (// operation with C.T.) - 0 quadrature droop fully anti-clockwise Not set (fully anti-clockwise) P4 Stability adjustments in standalone operation b) Install a D.C. analogue voltmeter (needle dial) cal. 100 V on terminals F+, F- and an A.C. voltmeter cal. 300 - 500 or 1000 V on the alternator output terminals. c) Check the rotating switch selection. The various adjustments during tests must be made by a qualified engineer. It is essential that the drive speed specified on the nameplate is reached before commencing adjustment. After operational testing, replace all access panels or covers. The AVR is used to make adjustments to the machine. any d) Voltage potentiometer P1 at minimum, fully anti-clockwise. e) Stability potentiometer P2 around 1/3 in from the anti-clockwise stop. f) Start the engine and set its speed to a frequency of 48 Hz for 50 Hz, or 58 for 60 Hz. Before using the AVR, make sure that the rotating switches have been correctly configured with AREP/SHUNT or PMG excitation g) Set the output voltage to the desired value using P1. - Rated voltage UN for solo operation (eg. 400 V) - Or UN + 2 to 4% for parallel operation with C.T. (eg. 410 V -) If the voltage oscillates, use P2 to make adjustments (try both directions), observing the voltage between F+ and F- (approx. 10 V D.C.). The best response time is obtained at the limit of the instability. If no stable position can be obtained, try selecting the fast position. a) Initial potentiometer settings (see table below) h) Check LAM operation: depending on the rotating switch selection. 4.2.1 - Setting up the R450 14 262/285 LEROY-SOMER Installation and maintenance 4531 en - 2012.03 / e R 450 AVRs i) Vary the frequency (speed) around 48 or 58 Hz according to the operating frequency, and check the change in voltage from that observed previously (~ 15%). j) Readjust the speed of the genset to its rated no-load value. Adjustments in parallel operation Before starting work on the alternator, make sure that the speed droop is identical for all engines. k) Preset for parallel operation (with C.T. connected to S1, S2) - Potentiometer P4 (quadrature droop) in 1/4 position in the case of 5A CT and at 1/2 position in the case of 1A CT. Apply the rated load (PF = 0.8 inductive). The voltage should drop by 2 to 3% (400 V). If it increases, check that neither V and W nor S1 and S2 have been reversed. l) The no-load voltages should be identical for all the alternators intended to run in parallel. - Couple the machines in parallel. - By adjusting the speed, try to obtain 0 kW power exchange. - By altering the voltage setting P1 on one of the machines, try to cancel (or minimise) the current circulating between the machines. - From now on, do not touch the voltage settings. m) Apply the available load (the setting is only correct if a reactive load is available) - By altering the speed, match the kW (or divide the rated power of the units proportionally) - By altering the quadrature droop potentiometer P4, match or divide the currents. 4.2.2 - Max. excitation adjustment (excitation ceiling) In standard setting, the potentiometer P3 is in maximum position. However, for applications requiring an overload protection (see 3.2.1.4), the excitation ceiling must be adjusted by using the following procedures in AREP and PMG. Method 1 : -Connect the AVR to the alternator -apply load to 110% of rated machine rated at PF=0.8, the green led is on and the red one is off. -record the excitation current value -adjust P3 until obtaining the red led flashing, the green one is always on. -decrease the load to 100% and make sure that the red led is off. - Increase the load at 115%, check that the red LED flashes during 90 seconds and that the excitation current is brought back to the above adjusted value (Iex adjusted). Method 2 : The rated excitation current (see machine plate) must be multiplied by 1.1 and the obtained value is used to set the potentiometer P3 at the right position. The following table must be used. Position of P3 I exc (A) 8h 1 9h 1.55 10h 1.95 11h 2.5 12h 3.15 13h 3.65 14h 4.25 15h 4.7 16h 5.15 12H 8H 16H P3 NB: In the case of a permanent short-circuit, the excitation current must reach 2.9 x Iex adjusted (limited to 9.5A), during 1 second in AREP or 10 seconds in PMG and shuts down to a value less than 1A. 15 263/285 LEROY-SOMER Installation and maintenance 4531 en - 2012.03 / e R 450 AVRs When the excitation current is set to the rated value, a voltage dip is observed in excitation current limit when the limitation is activated and the current limit is reached. 4.2.3 - Special type of use WARNING The excitation circuit F+, F- must not be left open when the machine is running: this will irreparably damage the AVR. The exciter is switched off by disconnecting the AVR power supply (1 wire on each auxiliary winding) - contact rating 16 A 250 V A.C. Connection is identical for resetting the AVR internal protection. If field weakening is used, provide field forcing. 4.2.3.3 - R450 field forcing (400V - 10A) X2 Z1 X1 Z2 E+ E- 4.2.3.1 - R450 (SHUNT) field weakening X2 Z1 X1 Z2 E+ E- t Diode - + Battery (B Volt) Exciter field winding Field forcing B Volt t Time The exciter is switched off by disconnecting the AVR power supply (1 wire - X1 or X2) Contact rating: 16 A - 250 V A.C. Applications B Volt Time t Guaranteed voltage build-up 12 (1A) 1-2s Parallel operation, de-energized 12 (1A) 1-2s 4.2.3.2 - R450 (AREP/PMG) field weakening Parallel operation, at standstill 12 (1A) 5 - 10 s Frequency starting 12 (1A) 5 - 10 s Sustained voltage on overload 12 (1A) 5 - 10 s X2 Z1 X1 Z2 E+ E- 16 264/285 LEROY-SOMER Installation and maintenance 4531 en - 2012.03 / e R 450 AVRs 4.3 - Electrical faults Fault Action Measurements Check/Cause The alternator builds up and its voltage is still correct when the battery is removed - Lack of residual magnetism No voltage at Connect a new battery The alternator builds up but its no load on of 4 to 12 V to terminals voltage does not reach the rated start-up F- and F+, respecting value when the battery is removed the polarity, for 2 to 3 seconds The alternator builds up but its voltage disappears when the battery is removed Voltage too low Check the drive speed - Check the connection of the voltage reference to the AVR - Faulty diodes - Armature short-circuit - Faulty AVR - Field windings disconnected - Revolving field coil open circuit. Check the resistance - Check the AVR connections and settings (AVR faulty) - Field windings short-circuited - Rotating diodes burnt out - Revolving field coil short-circuited - Check the resistance Correct speed Increase the drive speed (Do not touch the AVR voltage pot. (P1) before running at the correct speed) Speed too low Voltage too high Adjust AVR voltage potentiometer Adjustment ineffective - Faulty AVR - 1 faulty diode Voltage oscillations Adjust AVR stability potentiometer If no effect: try normal/fast recovery modes - Check the speed: possibility of cyclic irregularity - Loose connections - Faulty AVR - Speed too low when on load (or U/F knee-point set too high) Voltage correct at no load and too low when on load (*) Run at no load and check the voltage between F+ and F- on the AVR Voltage between F+ and FAREP/PMG < 10 V - Check the speed (or U/F knee-point set too high) Voltage between F+ and FAREP/PMG > 15 V - Faulty rotating diodes - Short-circuit in the revolving field coil. Check the resistance - Faulty exciter armature (*) Caution: For single-phase operation, check that the sensing wires coming from the AVR are correctly connected to the operating terminals. Voltage disappears during operation (**) Check the AVR, the surge suppressor, the rotating diodes, and replace any defective components The voltage does not return to the - Exciter winding open circuit rated value - Faulty exciter armature - Faulty AVR - Revolving field coil open circuit or short-circuited - Overload (see LED) (**) Caution: Internal protection may be activated (overload, open circuit, short-circuit) Caution: After operational testing or troubleshooting, replace all access panels or covers. 17 265/285 LEROY-SOMER Installation and maintenance R 450 AVRs 5 - SPARE PARTS 5.1 - Designation Description Type Voltage regulator R 450 (AVR) Code AEM 110 RE 031 5.2 - Technical support service Our technical support service will be pleased to provide any additional information you may require. When ordering spare parts, you should indicate the AVR type and code number. Address your enquiry to your usual contact. Our extensive network of service centres can dispatch the necessary parts without delay. To ensure correct operation and the safety of our machines, we recommend the use of original manufacturer spare parts. In the event of failure to comply with this advice, the manufacturer cannot be held responsible for any damage. 18 266/285 4531 en - 2012.03 / e LEROY-SOMER Installation and maintenance 4531 en - 2012.03 / e R 450 AVRs 19 267/285 www.leroy-somer.com 268/285 Appendix C - Common spare parts R340U Rental Power GENLUB ENGINE VOLVO TAD941GE GENCOOL 9.3. Radiator filler cap 330051142 X1 Radiator pressure cap 330052078 X1 Thermostat 330051467 X1 Thermostat seal 330051539 X1 Fan belt 330051419 X1 Rocker cover seal 330051468 X1 Water temperature sensor 330051466 X1 Oil pressure sensor 330051465 X1 Alternator belt 330051418 X1 x 25 L 330910094 x 208 L 330910095 x 20 L 330910098 x 60 L 330910099 x 210 L 330910100 X1 269/285 X1 330560243 X1 330570109 + 330570110 X1 330510015 + 330560617 X1 330560551 X2 330560634 X1 ALTERNATOR LEROY-SOMER LSA462VL12 Note Diode bridge 330410126 X1 Varistor 330410109 X1 For all technical assistance or spare part requests, contact your nearest SDMO agent. 270/285 SID PID PPID FMI 28 Throttle Voltage high, short to V+ Short to V+ 4 Throttle Voltage low, short to V- Short to V- Throttle #2 Position 3 Throttle Voltage high, short to V+ Short to V+ 4 Throttle Voltage low, short to V- Short to V- 14 Throttle voltage out of range 2 Vehicle invalid or missing 31 Vehicle speed mismatch Vehicle speed 91 91 132 Accelerator pedal position 3 Throttle Voltage high, short to V+ 4 Throttle Voltage low, short to V- 7 Throttle calibration invalid 8 PWM throttle abnormal pulse width 9 Throttle invalid (CAN value) 10 Throttle voltage out of range low 13 Throttle calibration aborted 14 Throttle voltage out of range 94 98 Not possible with Genset application FMI not determined for all VOLVO’s Not possible with genset application, codes declared by the CAN J1587 for VOLVO. Fuel rail pressure sensor 1 97 Comment 3 84 94 Description Throttle #3 Position 29 91 Perkins CID Volvo SPN Appendix D - List of John Deere - Volvo and Perkins fault codes John Deere 9.4. Fuel supply pressure extremely low 3 Fuel rail pressure input voltage high Short to V+ 4 Fuel rail pressure input voltage low Short to V- 5 Fuel rail pressure sensor open circuit 10 Fuel rail pressure lost detected 13 Fuel rail pressure higher than expected 16 Fuel supply pressure moderately high 17 Fuel rail pressure not developed 18 Fuel supply pressure moderately low 97 Water in fuel sensor 0 Water in fuel continuously detected 3 Water in fuel input voltage high Short to V+ 4 Water in fuel input voltage low Short to V- 16 Water in fuel detected 31 Water in fuel detected 98 Oil level sensor 1 Oil level value below normal 3 Oil level sensor input voltage high Short to V+ 4 Oil level sensor input voltage low Short to V- 5 Oil level sensor open circuit 271/285 100 102 273 PID PPID FMI 100 Engine oil pressure extremely low 3 Oil pressure sensor input voltage high Short to V+ 4 Oil pressure sensor input voltage low Short to V- 5 Oil pressure sensor open circuit 17 Engine oil pressure low 18 Engine oil pressure moderately low 31 Oil pressure detected, motor stopped 0 Manifold air pressure above normal 1 15 Manifold air pressure below normal Incoherent measurement of the oil pressure Manifold air pressure sensor input Short to V+ voltage high Manifold air pressure sensor input Short to Vvoltage low Manifold air pressure moderately low 16 Manifold air pressure low 0 Turbo speed too high 5 Turbo speed sensor circuit open 6 Sensor shorted to earth 8 Speed signal invalid Intermittent problem with speed information Manifold air temperature sensor 102 Manifold air pressure sensor 4 103 Turbo speed sensor 31 105 0 15 Manifold air temperature extremely high Manifold air temperature sensor input voltage high Manifold air temperature sensor input voltage low Manifold air temperature sensor open circuit Air temperature very high. 16 Manifold air temperature moderately high 3 4 5 106 Air inlet pressure sensor 0 3 5 107 Comment 1 3 106 Description Oil pressure sensor 2 105 Perkins 100 SID Volvo CID John Deere SPN 107 Air inlet pressure above normal Air inlet pressure sensor input voltage high Air inlet pressure sensor open circuit Air filter differential pressure sensor 0 3 4 5 31 Air filter restriction high Air filter differential pressure sensor input voltage high Air filter differential pressure sensor input voltage low Air filter differential pressure sensor open circuit Air filter restriction high 272/285 Short to V- 274 PID PPID FMI 108 3 4 17 110 110 15 Coolant temperature high least severe 16 Coolant temperature moderately high 17 Water temperature very low 31 Coolant temperature high 111 0 Engine coolant level low 1 Engine coolant level low 3 Coolant level sensor input voltage high 4 Coolant level sensor input voltage low 0 1 Value above normal Crankcase pressure sensor input voltage high Crankcase pressure sensor open circuit Fuel pressure sensor in the common rail Fuel pressure too low 3 Input voltage of the pressure sensor high Short to V+ Short to V- 153 Crankcase pressure sensor 5 157 4 Input voltage of the pressure sensor low 10 Loss of fuel pressure detected 16 Fuel pressure moderately high 17 Fuel ramp pressure not reached 18 Oil pressure moderately low 158 Battery voltage sensor 1 Voltage above normal 17 ECU power down error 160 Wheel speed sensor 2 164 ECM option, connected Coolant level sensor 3 168 High barometric pressure 5 4 158 Not use with EDC III and EMS2 Air pressure invalid High barometric pressure sensor short to high High barometric pressure sensor short to low Coolant temperature extremely high Coolant temperature sensor input voltage high Coolant temperature sensor input voltage low Coolant temperature sensor open circuit 3 153 Comment Coolant temperature sensor 0 111 Description Barometric pressure sensor 2 110 Perkins 108 SID Volvo CID John Deere SPN 164 Wheel speed input noise Injection pressure control 168 Electrical system voltage 2 Electrical system voltage low 273/285 sensor not 172 PID PPID FMI 172 4 5 15 16 174 0 15 16 Fuel temperature moderately high 31 Fuel temperature sensor faulty 4 175 Oil temperature sensor 0 Oil temperature extremely high 3 Oil temperature sensor input voltage high 4 Oil temperature sensor input voltage low 5 Oil temperature sensor open circuit 177 Transmission oil temperature sensor 9 189 190 228 Transmission oil temperature invalid Rated engine speed 190 0 Engine speed de rated 31 Engine speed de rated 190 Engine speed sensor 0 Overspeed extreme 2 Engine speed sensor data intermittent 9 Engine speed sensor abnormal update 11 Engine speed sensor signal lost 12 Engine speed sensor signal lost 15 Overspeed 16 Overspeed moderate 13 Engine timing abnormal calibration 261 252 252 234 253 Speed sensor calibration Software 11 281 Comment Inlet air temperature sensor for PERKINS Ambient air temperature sensor input Inlet air temperature sensor voltage high input voltage high Ambient air temperature sensor input Inlet air temperature sensor voltage low input voltage low Ambient air temperature sensor open circuit High Inlet air temperature alarm-warning High Inlet air temperature alarm-action alert Fuel temperature sensor Fuel temperature high most severe Fuel temperature sensor input voltage high Fuel temperature sensor input voltage low Fuel temperature high 3 175 Description Ambient air temperature sensor 3 174 Perkins 172 SID Volvo CID John Deere SPN Incorrect engine software Check system parameters 2 Incorrect parameters 3 Action alert output open/short to B+ 4 Action alert output short to ground 5 Action alert output open circuit 281 Action alert output status 274/285 Not possible with Genset application 282 285 PID PPID FMI 3 Overspeed output open/short to B+ 4 Overspeed output short to ground 285 4 323 324 286 Oil pressure output open/short to B+ 4 Oil pressure output short to ground 5 Oil pressure output open circuit 323 Shutdown output status 3 Shutdown output open/short to B+ 4 Shutdown output short to ground 5 Shutdown output open circuit 324 Warning output status 3 Warning output open/short to B+ 4 Warning output short to ground 5 Warning output open circuit 0 15 Temperature in the EGR extremely high Input voltage of the temperature sensor Short to V+ high Input voltage of the temperature sensor Short to Vlow Temperature in the EGR high 16 Temperature in the EGR moderately high Temperature sensor in the EGR valve. 3 4 443 ENGINE RUN output status 3 Engine run output open/short to B+ 4 Engine run output short to B- 523 Gear selection 9 608 132 608 98 611 262 Gear selection invalid Not possible with Genset application Data link faulty J1587 Start/Stop redundancy / J1939 communication bus Redundancy of the accelerator Redundancy of the Stop/start information Injector wiring status 250 608 620 Comment Coolant temperature output status Coolant temperature lamp open/short to B+ Coolant temperature lamp short to ground Oil pressure output status 3 412 443 Description Overspeed output status 3 286 Perkins 282 SID Volvo CID John Deere SPN 3 Injector wiring shorted to power source 4 Injector wiring shorted to ground 232 5 Volt sensor power supply 3 Sensor power supply open/short to B+ 4 Sensor power supply short to ground 275/285 FMI not VOLVO informed by 626 PID PPID FMI 45 3 4 5 627 Perkins SID Volvo CID John Deere SPN Description Comment Start enable device (intake heater and ether) Start enable device output short to B+ Not used, the control panel Start enable device output short to is in charge of managing the ground start enable device Start enable device output open circuit Power supply 1 Injector supply voltage problem 4 For 6125HF070 only 628 240 ECU unswitched power missing For 6068HF275 VP44 only Battery voltage below the operating For John DEERE Tiers III voltage Memory fault in EMS2 629 254 ECU status/controller error 18 2 RAM cell test failure 8 CPU watchdog reset test failure 11 Main and fuelling ASIC test fail 12 RAM address test failure 13 Watchdog trip failure ECU to injection pump communication Possible only error 6068HF475 VP44 Data set memory EEPROM 19 630 253 632 636 with Injection status 2 Fuel shutoff error 5 Fuel shutoff non-functional Pump position sensor/Cam position Pump position or CAM sensor/Speed sensor CAM position in function of the Pump position sensor/cam position type of injection sensor input noise Permanent loss of signal High impedance of the position sensor or circuit open Sensor short to ground Pump position sensor/cam position sensor input missing Not informed by VOLVO Pump position sensor/cam position sensor input pattern error Crank position sensor/Speed sensor flywheel Crank position input noise 21 2 3 5 6 8 9 10 637 CIU module status 22 2 3 8 Permanent loss of signal High impedance of the position sensor or open circuit Sensor short to ground Crank position/Cam position out of synchronisation Crank position input missing 9 Not informed by VOLVO 10 Crank position sensor input pattern error 5 6 7 276/285 639 247 231 PID PPID FMI 2 Bus Off error 9 Passive bus error 11 Data registers read back failure 12 Loss of message error 13 Bus CAN error Comment Engine shutdown vehicle status 11 Engine shutdown vehicle request invalid 31 Engine shutdown vehicle request Status of the Turbo with variable geometry Supply voltage of the Turbo actuator low Error in communication between the ECU and the TGV actuator Error in position of the TGV Temperature of the actuator moderately high. Fan supply 641 4 12 13 16 647 3 5 1 1 651 Injector outside specifications 1 Injector outside specifications 2 4 Short circuit high side to B+ Short circuit high side to low side or low side to B+ Short circuit high or low side to ground 5 Cylinder #1 circuit open 6 Cylinder #1 circuit shorted Cylinder #1 balancing error/mechanical failure Cylinder #1 unknown error/mechanical failure Cylinder #2 injector status 11 2 Open circuit 0 7 2 Short circuit to earth Cylinder #1 injector status 3 652 Description Communication status 640 651 Perkins SID Volvo CID John Deere SPN 652 0 Injector outside the specifications 1 Injector outside the specifications 2 4 Short circuit high side to B+ Short circuit high side to low side or low side to B+ Short circuit high or low side to ground 5 Cylinder #2 circuit open 6 Cylinder #2 circuit shorted Cylinder #2 balancing error/mechanical failure Cylinder #2 unknown error/mechanical failure 3 7 11 277/285 Recalibration of the injectors required Recalibration of the injectors required Recalibration of the injectors required Recalibration of the injectors required PID 653 3 3 653 PPID FMI 0 Injector outside the specifications 1 Injector outside the specifications 2 4 Short circuit high side to B+ Short circuit high side to low side or low side to B+ Short circuit high or low side to ground 5 Cylinder #3 circuit open 6 Cylinder #3 circuit shorted Cylinder #3 balancing error/mechanical failure Cylinder #3 unknown error/mechanical failure Cylinder #4 injector status 7 11 4 4 654 0 Injector outside the specifications 1 Injector outside the specifications 2 4 Short circuit high side to B+ Short circuit high side to low side or low side to B+ Short circuit high or low side to ground 5 Cylinder #4 circuit open 6 Cylinder #4 circuit shorted Cylinder #4 balancing error/mechanical failure Cylinder #4 unknown error/mechanical failure Cylinder #5 injector status 3 7 11 655 5 5 Description Comment Cylinder #3 injector status 3 654 Perkins SID Volvo CID John Deere SPN 655 0 Injector outside the specifications 1 Injector outside the specifications 2 4 Short circuit high side to B+ Short circuit high side to low side or low side to B+ Short circuit high or low side to ground 5 Cylinder #5 circuit open 6 Cylinder #5 circuit shorted Cylinder #5 balancing error/mechanical failure Cylinder #5 unknown error/mechanical failure 3 7 11 278/285 Recalibration of the injectors required Recalibration of the injectors required Recalibration of the injectors required Recalibration of the injectors required Recalibration of the injectors required Recalibration of the injectors required PID 656 6 6 656 PPID FMI 0 Injector outside the specifications 1 Injector outside the specifications 2 4 Short circuit high side to B+ Short circuit high side to low side or low side to B+ Short circuit high or low side to ground 5 Cylinder #6 circuit open 6 Cylinder #6 circuit shorted Cylinder #6 balancing error/mechanical failure Cylinder #6 unknown error/mechanical failure Glow plug relay status 7 11 39 677 678 39 3 Glow plug relay voltage high 5 Glow plug relay voltage low 3 3 Start relay control short circuit to high 4 Start relay control short circuit low 5 Start relay control open circuit 3 ACM 8 Volt DC supply open/short to B+ ACM 8 Volt DC supply open/short to ground Regulation sensor of the injection pressure control Secondary speed sensor Secondary engine speed sensor data intermittent Secondary engine speed sensor loss of signal Loss of signal/sensor failure Inlet air heater signal/Preheat detection Inlet air heater signal high 5 Inlet air heater signal low 4 42 342 2 11 12 729 70 810 Vehicle speed 2 861 861 Calculated vehicle speed input noise Not possible with Genset application Diagnostic output status 3 Diagnostic output open/short to B+ 4 Diagnostic output short to ground 898 CAN throttle status 9 970 Recalibration of the injectors required Recalibration of the injectors required 8 Volt power supply 3 723 Comment Start relay status 41 679 Description Cylinder #6 injector status 3 676 Perkins SID Volvo CID John Deere SPN 6 2 31 971 Speed value invalid or missing Auxiliary engine shutdown switch status EMS Auxiliary engine shutdown switch signal Not used invalid Auxiliary engine shutdown switch active External engine de rate switch status 31 External engine de rate switch active 279/285 Not used PID PPID FMI 1069 Comment 2 Tire size error 9 Tire size invalid 31 Tire size error 5 6 Feed pump of the fuel circuit High impedance at the terminals of the pump or open circuit Pump coil short to ground 12 Pump defective 1076 Not possible with Genset application Fuel Injection pump status 0 Pump control valve closure too long Injection DE10 1 Pump control valve closure too short Injection DE10 2 Pump detected defect Injection VP44 3 Pump solenoid current high Injection DE10 5 Pump solenoid circuit open Injection DE10 6 Pump solenoid circuit severely shorted Injection DE10 7 Pump control valve closure not detected Injection DE10 10 Pump solenoid circuit moderately shorted Injection DE10 13 Pump current decay time invalid 1077 Injection DE10 Fuel injection pump controller status 7 Attempting to fuel without command 11 Pump supply voltage out of range 12 Pump self test error 19 Pump detected communication error 31 Pump initiated engine protection 1078 7 11 31 1079 232 1080 ECU/Pump timing status ECU/Pump timing moderately out of synchronisation ECU/Pump timing speed out of synchronisation ECU/Pump timing extremely out of synchronisation Sensor supply voltage (+5 Volt) Analog throttle reference 3 Sensor supply voltage high 4 Sensor supply voltage low Sensor supply voltage (Oil pressure)/+5V sensor supply 2 Sensor supply voltage high 211 3 4 1109 Sensor supply voltage low Engine/ECU status 31 1110 Engine shutdown warning Engine status 31 268 Engine shutdown Check parameters 2 1136 Description Tire size status 1075 1111 Perkins SID Volvo CID John Deere SPN 55 Programmed parameter fault ECU Temperature 0 ECU temperature extremely high 16 ECU temperature moderately high 280/285 > 5,5 Volt < 4,44 Volt pressure, Coolant > 5,5 Volt < 4,40 Volt temp, fuel PID PPID FMI Perkins SID Volvo CID John Deere SPN 3 4 1180 0 Turbine temperature extremely high Short to V+ 16 Turbine temperature moderately high Short to V- 173 1239 Exhaust gas temperature sensor Status of the pressure system of the common rail 96 1347 Pump control valve status 3 Pump control valve current high 5 Pump control valve error/mismatch 7 Fuel rail pressure control error 10 Pump control valve fuel flow not detected 1348 Pump control valve #2 status 5 1485 5 Pump power relay status 2 Only for 6081HF070 ECU main relay of VOLVO EMS/EDC Pump power relay fault ECU main relay short circuit high 3 1568 Torque curve selection PID PPID Torque curve input voltage high 9 Torque curve selection missing FMI 1569 Perkins SID Torque curve selection invalid 4 Volvo CID 2 John Deere SPN Pump control valve #1 status for 6081HF070 Pump control valve #2 error/mismatch Pump control valve #2 fuel flow not detected 10 1485 Comment Input temperature of the TGV compressor Input voltage of the temperature sensor Short to V+ high Input voltage of the temperature sensor Short to Vlow Input temperature of the TGV turbine 1172 1184 Description Description Fuel supply status 31 Fuel de rate 1 Fan speed zero or absent 2 Fan speed signal erratic Fan speed more than 300 rpm above its setpoint for at least 180s Fan speed more than 300 rpm below its setpoint for at least 180s ECU status 1639 Fan speed 16 18 2000 6 Vehicle ID missing 13 Security violation 281/285 Comment PID PPID FMI 2630 Description Comment Air temperature at the air cooler outlet 0 Air temperature extremely high 3 Sensor input voltage high Short to V+ 4 Sensor input voltage low Short to V- 15 Air temperature high 16 Air temperature moderately high 2659 Flow level of the EGR valve 2 Calculated EGR flow not valid 15 Calculated EGR flow rather high 17 Calculated EGR flow rather low Air temperature at turbo compressor outlet Temperature at compressor outlet moderately high Statuses of the EGR valve 2790 16 2791 Perkins SID Volvo CID John Deere SPN 19 2 Valve position signal not valid 3 Input voltage of the position sensor high 4 13 Input voltage of the position sensor low Short to VInability of the EGR valve to reach the expected position The EGR valve is out of calibration 31 Error in position of the EGR valve 7 2795 520192 8 Position of TGV actuator The actuator does not respond or is not in the expected position Common supply voltage of the sensors, output #1 Supply voltage of the sensor too high Supply voltage of the sensor shorted to ground Common supply voltage of the sensors, output #2 Supply voltage of the sensor too high Supply voltage of the sensor shorted to ground Common supply voltage of the sensors, output #3 Supply voltage of the sensor too high Supply voltage of the sensor shorted to ground Common supply voltage of the sensors, output #4 Supply voltage of the sensor too high Supply voltage of the sensor shorted to ground Common supply voltage of the sensors, output #5 Supply voltage of the sensor too high Supply voltage of the sensor shorted to ground Cooling status of the piston 520194 4 Status of the starting request input 520195 6 Stop request on CIU 7 3509 3 3510 3 3511 3 3512 3 3513 3 282/285 Short to V+ Exceeding +5 volts Exceeding +5 volts Exceeding +5 volts Exceeding +5 volts Exceeding +5 volts SAE J1939-73 : March 2004 FMI and Description FMI=0—DATA VALID BUT ABOVE NORMAL OPERATIONAL RANGE - MOST SEVERE LEVEL The signal communicating information is within a defined acceptable and valid range, but the real world condition is above what would be considered normal as determined by the predefined most severe level limits for that particular measure of the real world condition (Region e of the signal range definition) Broadcast of data values is continued as normal. Broadcast of data values is continued as normal. FMI=1—DATA VALID BUT BELOW NORMAL OPERATIONAL RANGE - MOST SEVERE LEVEL The signal communicating information is within a defined acceptable and valid range, but the real world condition is below what would be considered normal as determined by the predefined least severe level limits for that particular measure of the real world e of the signal range definition). condition (Region Broadcast of data values is continued as normal. FMI=2—DATA ERRATIC, INTERMITTENT OR INCORRECT Erratic or intermittent data includes all measurements that change at a rate that is not considered possible in the real world condition and must be caused by improper operation of the measuring device or its connection to the module. Broadcast of data value is substituted with the “error indicator” value. Incorrect data includes any data not received and any data that is exclusive of the situations covered by FMIs 3, 4, 5 and 6. Data may also be considered incorrect if it is inconsistent with other information collected or known about the system. FMI=3—VOLTAGE ABOVE NORMAL, OR SHORTED TO HIGH SOURCE a. A voltage signal, data or otherwise, is above the predefined limits that bound the range (Region e of the signal range definition). Broadcast of data value is substituted with the “error indicator” value. b. Any signal external to an electronic control module whose voltage remains at a high level when the ECM commands it to low. Broadcast of data value is substituted with the “error indicator” value. FMI=4—VOLTAGE BELOW NORMAL, OR SHORTED TO LOW SOURCE a. A voltage signal, data or otherwise, is below the predefined limits that bound the range (Region e of the signal range definition). Broadcast of data value is substituted with the “error indicator” value. b. Any signal external to an electronic control module whose voltage remains at a low level when the ECM commands it to high. Broadcast of data value is substituted with the “error indicator” value. FMI=5—CURRENT BELOW NORMAL OR OPEN CIRCUIT a. A current signal, data or otherwise, is below the predefined limits that bound the range (Region e of the signal range definition). Broadcast of data value is substituted with the “error indicator” value. b. Any signal external to an electronic control module whose current remains off when the ECM commands it on. Broadcast of data value is substituted with the “error indicator” value. FMI=6—CURRENT ABOVE NORMAL OR GROUNDED CIRCUIT a. A current signal, data or otherwise, is above the predefined limits that bound the range. (Region e of the signal range definition). Broadcast of data value is substituted with the “error indicator” value. b. Any signal external to an electronic control module whose current remains on when the ECM commands it off. Broadcast of data value is substituted with the “error indicator” value. FMI=7—MECHANICAL SYSTEM NOT RESPONDING OR OUT OF ADJUSTMENT Any fault that is detected as the result of an improper mechanical adjustment or an improper response or action of a mechanical system that, with a reasonable confidence level, is not caused by an electronic or electrical system failure. This type of fault may or may be directly associated with the value of general broadcast information. FMI=8—ABNORMAL FREQUENCY OR PULSE WIDTH OR PERIOD To be considered in cases of FMI 4 and 5. Any frequency or PWM signal that is outside the predefined limits which bound the signal range for frequency or duty cycle (outside Region b or the signal definition). Also if the signal is an ECM output, any signal whose frequency or duty cycle is not consistent with the signal which is emitted. Broadcast of data value is substituted with the “error indicator” value. FMI=9—ABNORMAL UPDATE RATE Any failure that is detected when receipt of data via the data link or as input from a smart actuator or smart sensor is not at the update rate expected or required by the ECM (outside Region c of the signal range definition). Also any error that causes the ECM not to send information at the rate required by the system. This type of fault may or may be directly associated with the value of general broadcast information. FMI=10—ABNORMAL RATE OF CHANGE Any data, exclusive of the abnormalities covered by FMI 2, that is considered valid but whose data is changing at a rate that is outside the predefined limits that bound the rate of change for a properly functioning system (outside Region c of the signal range definition). Broadcast of data values is continued as normal. 283/285 FMI=11—ROOT CAUSE NOT KNOWN It has been detected that a failure has occurred in a particular subsystem but the exact nature of the fault is not known. Broadcast of data value is substituted with the “error indicator” value. FMI=12—BAD INTELLIGENT DEVICE OR COMPONENT Internal diagnostic procedures have determined that the failure is one which requires the replacement of the ECU, used here to mean the packaged unit that includes some microprocessor and its associated components and circuits. It can be assumed that the communications subsystem is not the part that has failed, and the manufacturer has determined that there is no serviceable component smaller than the ECU involved in the failure. Broadcast of data value is substituted with the “error indicator” value if appropriate, as there may or may not be any broadcast involved. This error is to include all internal controller trouble codes that can not be caused by connections or systems external to the controller. FMI=13—OUT OF CALIBRATION A failure that can be identified to be the result of not being properly calibrated. This may be the case for a subsystem which can identify that the calibration attempting to be used by the controller is out of date. Or it may be the case that the mechanical subsystem is determined to be out of calibration. This failure mode does not relate to the signal range definition as do many of the FMIs. FMI=14—SPECIAL INSTRUCTIONS “Special Instructions” is the FMI to be used when the on-board system can isolate the failure to a small number of choices but not to a single point of failure. When the FMI is used, there is clear necessity for the service technician to take some action to complete the specific diagnosis, and the manufacturer has provided instructions for the completion of that diagnosis. There are two cases where this will be used: 1. for emission-related diagnostics where the particular failure cannot be separated between a sensor out of range and the case where the actual value is at the edge of a diagnostic region, and 2. for the older SPN 611 to 615 where the problem is in determining which of two or more circuits (which may interact) is the one that needs repair. SPNs 611 through 615 are defined as “System Diagnostic Codes” and are used to identify failures that cannot be tied to a specific field replaceable component. Specific subsystem fault isolation is the goal of any diagnostic system, but for various reasons this cannot always be accomplished. These SPNs allow the manufacturer some flexibility to communicate non-“specific component” diagnostic information. Since SPNs 611-615 use the standard SPN/FMI format it allows the use of standard diagnostic tools, electronic dashboards, satellite systems and other advanced devices that scan Parameter Groups containing the SPN/FMI formats. Because manufacturer defined codes are not desirable in terms of standardization, the use of these codes should only occur when diagnostic information cannot be communicated as a specific component and failure mode. Possible reasons for using a System Diagnostic Code include: 1. Cost of specific component fault isolation is not justified, or 2. New concepts in Total Vehicle Diagnostics are being developed, or 3. New diagnostic strategies that are not component specific are being developed. Due to the fact that SPNs 611-615 are manufacturer defined and are not component specific, FMIs 0-13 and 15-31 have little meaning. Therefore, FMI 14, “Special Instructions”, is usually used. The goal is to refer the service personnel to the manufacturer's troubleshooting manual for more information on the particular diagnostic code. This failure mode does not relate to the signal range definition as do many of the FMIs. This type of fault may or may be directly associated with the value of general broadcast information. FMI=15—DATA VALID BUT ABOVE NORMAL OPERATING RANGE - LEAST SEVERE LEVEL The signal communicating information is within a defined acceptable and valid range, but the real world condition is above what would be considered normal as determined by the predefined least severe level limits for that particular measure of the real world condition (Region i of the signal range definition). Broadcast of data values is continued as normal. FMI=16—DATA VALID BUT ABOVE NORMAL OPERATING RANGE - MODERATELY SEVERE LEVEL The signal communicating information is within a defined acceptable and valid range, but the real world condition is above what would be considered normal as determined by the predefined moderately severe level limits for that particular measure of the real world condition (Region k of the signal range definition). Broadcast of data values is continued as normal. FMI=17—DATA VALID BUT BELOW NORMAL OPERATING RANGE - LEAST SEVERE LEVEL The signal communicating information is within a defined acceptable and valid range, but the real world condition is below what would be considered normal as determined by the predefined least severe level limits for that particular measure of the real world condition (Region h of the signal range definition). Broadcast of data values is continued as normal. FMI=18—DATA VALID BUT BELOW NORMAL OPERATING RANGE - MODERATELY SEVERE LEVEL The signal communicating information is within a defined acceptable and valid range, but the real world condition is below what would be considered normal as determined by the predefined moderately severe level limits for that particular measure of the real world condition (Region j of the signal range definition). Broadcast of data values is continued as normal. FMI=19—RECEIVED NETWORK DATA IN ERROR Any failure that is detected when the data received via the network is found substituted with the “error indicator” value (i.e. FE16, see J1939-71). This type of failure is associated with received network data. The component used to measure the real world signal is wired directly to the module sourcing the data to the network and not to the module receiving the data via the network. The FMI is applicable to Region f and g of the signal range definition. This type of fault may or may be directly associated with the value of general broadcast information. 284/285 FMI=20-30—RESERVED FOR SAE ASSIGNMENT FMI=31—CONDITION EXISTS Used to indicate that the condition that is identified by the SPN exists when no more applicable FMI exists or in cases when the reported SPN name spells out the component and a non-standard failure mode. This type of fault may or may be directly associated with the value of general broadcast information. This FMI will mean “not available” when the associated SPN is also “not available” as when the remainder of the packet is filled with binary ones after all data has been transmitted. 285/285